Front Turn Signal Relocation Kit Instruction Sheet - Harley
Contents
1. Item Description Quantity Part Number 1 Stalk front turn signal relocation left 68538 06 2 Stalk front turn signal relocation right 68697 06 3 Socket head cap screw 5 16 24 x 5 8 in Grade 8 2 2698A 4 Lock washer split 5 16 in 2 7042 5 Button head self tapping screw 3 8 16 x 2 1 4 in Grade 8 2 4047 6 P clamp 5 16 in cushioned 10059A 7 Wire tie 8 10065 8 Lock washer internal tooth 5 16 in 2 7127 9 Acorn nut tall 5 16 24 chrome 2 7720 Items mentioned in text but not included in kit A Wire notch B Wire slot C Lower fork bracket D Original equipment pinch screw 2 E Brake line retaining cap screw and washer F Feed turn signal wires through P clamp as shown G White 3 place left turn signal connector H Black 3 place right turn signal connector J03589 5of52. follow the instructions to remove the seat Retain all seat mounting hardware WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a J03589 NOTE When moving the fuel tank back take care not to damage the fuel gauge wires clipped to the frame under the left side of the fuel tank 5 Return to FUEL TANK REMOVAL in the Service Manual Follow the steps to remove the front and rear fuel tank mounting hardware Move the fuel tank back on the frame to gain access to the tabs on the steering head harness shield 6 See Figure 1 Disengage the tabs 2 from the holes 3 on each side of the frame and remove the shield 1 7 Pull the wire harness down from inside the frame enough to disconnect the white left and black right 3 place turn signal connectors Set aside the frame side connector halves 8 Refer to the AMP MULTILOCK ELECTRICAL CONNEC TORS section of the Service Manual to remove the socket terminals from the lamp side connector halves Make note of the wire colors installed in the cavities of each con nector which should be a Black wire in cavity 1 b Violet wire in cavity 2 and c Blue wire if installed in cavity 3 is00692 ara Pe eo E of Harness shield Harness shield tab 2 Hole in frame 2 Steering head plug 2 Po
3. al harnesses earlier 31 Refer to the AMP MULTILOCK ELECTRICAL CONNEC TORS section of the Service Manual to install the socket terminals from the the turn signal harnesses into the cor rect lamp side connector halves Unless noted differently on removal a install the Black wire into cavity 1 b the Violet wire to cavity 2 and c the Blue wire if installed to cavity 3 32 See Figure 1 Feed the assembled right side black turn signal connector from the outside through the grommet 4 in the right side of the frame behind the steering head Feed the assembled left side white connector through the grommet in the left side of the frame 33 Re connect the left and right connector halves to the same color mating connector halves coming from the frame 34 Refer to the Service Manual and follow the instructions given to temporarily re install the maxi fuse 35 Test the turn signals to ensure they function correctly IWAN IN Be sure that steering is smooth and free without interfer ence Interference with steering could result in loss of vehicle control and death or serious injury 00371a e Be sure wires do not pull tight when handlebars are turned fully to left or right fork stops J03589 36 Use wire ties from the kit as needed to secure the har nesses so they do not interfere with steering function or become entangled or pinched Wire tie any excess harness length so it can be stowed inside the steering
4. amp into the stalk through the wire slot B near the lamp end Obtain a socket head cap screw 3 and split lock washer 4 from the kit Place the lock washer onto the screw threads and insert the screw into the deep recess in the stalk and through the hole Position the turn signal lamp against the end of the stalk and thread the screw into the lamp housing Place the assembled stalk and lamp in the mounting position on the lower fork bracket C and align the lamp to face forward and parallel to the ground While holding the alignment remove the assembly and tighten the lamp mounting screw to 72 84 in Ibs 8 1 9 5 Nm Verify that the front suspension is unloaded front wheel raised slightly off the ground then remove and discard the pinch screw D from the lower fork bracket Fasten the stalk assembly to the lower fork bracket with a new longer pinch screw 5 from the kit taking notice of the following a This is a thread cutting screw and can be prone to cross threading if not careful Finger tighten the first few threads as far as possible to feel for and avoid cross threading b With the stalk centered relative to the fork bracket verify that the lamp is facing forward and parallel to the ground If not repeat step 22 c Verify that the stalk wire notch is facing downward If not switch this assembly to the other side of the vehicle and repeat steps 19 to 24b with the remaining lamp and kit items d Veri
5. cMOTOR HARLEY DAVIDSON WY J03589 INSTRUCTIONS REV 2006 06 20 FRONT TURN SIGNAL RELOCATION KIT GENERAL Kit Number 68564 06 Models This kit fits 2006 and later Dyna model motorcycles except FXDSE relocating the front turn signal from the handlebars to the lower fork bracket Additional Parts Required WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 4 and Table 1 INSTALLATION Support the vehicle upright on a center stand with the front wheel raised slightly off the ground See FUEL TANK REMOVAL in the Service Manual Follow the steps to purge the fuel line of high pressure gasoline and disconnect the fuel line e N WARNING To prevent accidental vehicle start up which could cause death or serious injury remove maxi fuse before pro ceeding 00251a 3 Follow the instructions in the Service Manual to remove the maxi fuse e Refer to the Service Manual and
6. damage the fuel tank or lamp housing J03589 Figure 3 Left Side Turn Signal Removal 15 Remove the acorn nut 8 ball receptacle and internal tooth lock washer 6 from the rear view mirror stalk 7 Discard the ball receptacle lock washer and acorn nut NOTES FXD FXDC and FXDL models The turn signal wires are routed alongside the hand control wires through retainers fas tened to the outside of the handlebar FXDB models The turn signal wires are routed through grommets on the underside of the handlebar switch housings then inside a sleeve along with the hand control wires through retainers fastened to the outside of the handlebar FXDWG models The turn signal wires are routed through grommets on the underside of the handlebar switch housings then inside the handlebars ALL models To make removal easier a smooth tape such as electrical tape can be used to cover the socket terminals at the ends of the turn signal wires 16 Completely remove the turn signals and wires from the handlebar 2of5 17 18 19 Models with turn signal wires OUTSIDE the handlebar switch housings FXD FXDC and FXDL models While supporting the turn signal lamp pull the turn signal wires upward and outward through the wire retainers Set the signal lamps and wires aside for re installation Models with turn signal wires INSIDE the handlebar switch housings FXDB and FXDWG models a See the HANDLEBAR SWITCH ASSEMBLIES
7. fy that the exiting wire is centered in the wire notch at the stalk base and is not being pinched by the stalk against the fork bracket With the stalk centered on the fork bracket all orientations correct AND the exiting wire centered in the stalk wire notch torque the pinch bolt to 30 35 ft lbs 40 7 47 5 Nm Repeat the lamp and stalk installation for the opposite side of the vehicle Remove the cap screw and washer E that mount the front brake line s to the underside of the lower fork bracket and set it aside Obtain the P clamp 6 from the kit and loosely install it with the cap screw removed from the previous step Insert the screw through the new P clamp and the brake line mounting to the underside of the fork bracket NOTE P clamp orientation should be opposite of the brake line mounting 29 See Figure 4 Route the wires behind the fork tubes Feed both signal wires through the new P clamp in the direc 3 of 5 tion F opposite that from which they originated so the wire is heading back toward its own turn signal lamp Pull the wires through the P clamp so they are just pulled taut and torque the cap screw to 8 3 10 0 ft lbs 11 3 13 6 Nm The wires from the right side turn signal should now be toward the right side of the vehicle and the left side wires toward the left 30 Obtain the white left item G and black right item H 3 place turn signal connectors removed from the turn sign
8. head 37 Push the wire harness back up inside the frame behind the steering head Position the harness shield 1 to the underside of the top bar with the tabs 2 inside and push upward until the tabs engage the holes 3 on each side of the frame WARNING To prevent accidental vehicle start up which could cause death or serious injury remove maxi fuse before pro ceeding 00251a WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 38 See FUEL TANK INSTALLATION in the Service Manual Follow the steps to re install the fuel tank and re connect the fuel line 39 Refer to the Service Manual and follow the instructions given to re install the maxi fuse 40 Follow the instructions in the Service Manual to re install the seat WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 41 Adjust the mirrors for proper field of vision and tighten the acorn nuts to 12 ft lbs 16 Nm Check mirror adjustment and reposition if necessary 4of5 SERVICE PARTS is00698a Figure 4 Service Parts Front Turn Signal Relocation Kit Table 1 Service Parts Table
9. n Figure 1 Harness Shield Removal 1of5 is00693 o On et _ Gy Right side turn signal Jam nut Ball stud Ball stud clamp Retainer Lock washer Rear view mirror stalk Acorn nut Brake master cylinder housing ONORA ON is00694a Left side turn signal Jam nut Ball stud Ball stud clamp Ball receptacle Lock washer Rear view mirror stalk Acorn nut ON OT BN a Clutch hand lever bracket 10 11 12 13 14 Figure 2 Right Side Turn Signal Removal See Figure 2 Using 5 8 in and 1 2 in wrenches hold the right side ball stud clamp 4 and loosen the jam nut 2 Hold the retainer 5 with the 5 8 in wrench and unscrew the ball stud clamp from the retainer Discard the ball stud clamp Unscrew and discard the ball stud 3 and jam nut from the right side turn signal 1 Remove the turn signal lamp and allow it to hang down taking care not to damage the fuel tank or lamp housing Remove the retainer 5 and internal tooth lock washer 6 from the rear view mirror stalk 7 Discard the lock washer and retainer See Figure 3 Hold the left side ball stud clamp 4 and loosen the jam nut 2 Unscrew the ball stud clamp from the ball receptacle 5 Discard the ball stud clamp Unscrew and discard the ball stud 3 and jam nut from the left side turn signal 1 Remove the turn signal lamp and allow it to hang down taking care not to
10. ousing to the handlebar per the INSTALLATION instructions in the Manual h Repeat for the opposite side switch housing ALL models See Figure 2 Obtain the acorn nut 8 and a new lock washer 6 from the kit Fasten the mirror stalk to the front brake master cylinder housing 9 with the acorn nut and lock washer but do not fully tighten at this time See Figure 3 Obtain the acorn nut 8 and a new lock washer 6 from the kit Fasten the mirror stalk to the clutch hand lever bracket 9 with the acorn nut and lock washer but do not fully tighten at this time See Figure 4 Obtain the turn signal stalks from the kit The left side 1 and right side 2 stalks can be identified by the part numbers found at the wide end or by posi tioning the stalk with the wire notch A at the bottom against the mounting location on the lower fork bracket NOTES Both left side and right side turn signal lamps are identical J03589 The wire harness coming from the turn signal lamp has a flat cross section similar to the wire slot B near the lamp end of the stalk For best appearance align the harness along its full length to determine the flat side that will lie against the stalk when the lamp is attached Insert the harness into the slot in that orien tation to avoid a half twist in the wire harness at the lamp 20 21 22 23 24 25 26 27 28 Carefully feed the length of wire from the turn signal l
11. section of the Service Manual Remove one of the handlebar switch housings from the handlebar following the correct RIGHT or LEFT HANDLEBAR SWITCH REMOVAL instructions Support the hand lever so it is not damaged b Follow the DISASSEMBLY instructions to separate the upper and lower switch housings Carefully cut the wire tie inside the switch housing and identify the wires coming from the turn signal lamp not the turn signal switch on the handlebar control pod c While supporting the turn signal lamp pull the turn signal wires upward and outward through the han dlebar wire harness bundle until the turn signal wires are free of the others up to the switch housing grommet d Remove the tape used to cover the socket terminals at the ends of the turn signal wires Pull the wire har ness through the hole in the switch housing along with the grommet e Remove the grommet from the turn signal wire har ness and install it back in the hole in the switch housing Set the signal lamp and wires aside for re installation f Remove the wire tie cut earlier inside the switch housing and re assemble the wire bundle to the metal bracket at the bottom of the housing using a new wire tie from the kit It may be necessary to use a T 15 TORX drive head to loosen the bracket in order to install the wire tie g Re assemble the upper and lower switch housings per the ASSEMBLY instructions in the Service Manual Install the switch h
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