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PASSING LAMP/TURN SIGNAL RELOCATION KIT - Harley

1. 5 Slip the two inch 50 8 mm long section of encapsulating dual wall shrink tube 5 over the conduit and wires 1 of 4 Please dispose of materials responsibly 6 Use aheat gun or suitable radiant heating device to shrink the tubing to the wires and conduit 7 Assemble the switches and switch housings to the handlebar per service manual instructions tucking the shrink sealed wire ends back inside the switch housings Repeat on the opposite side of the vehicle 8 Install the new turn signals from the kit using the Con nector Method as shown below Refer to the wiring dia grams and the AMP MULTI LOCK ELECTRICAL CON NECTORS in the service manual 9 See Figure 2 Install the mirrors using lockwashers and spacers on the mirror shaft and secure with an acorn nuts from the kit If the acorn nut bottoms out without tightening remove the acorn nut add a spacer from the kit and install acorn nut and tighten isO6670 1 Spacer 2 Lock washer 3 Acorn nut Figure 2 Mirror Hardware For 2010 and Earlier Preparation 1 Determine Method for Installation Connector Method This is the preferred means of rewiring the turn signals It involves crimping the terminals on wires and insert in proper cavities as noted to enable plug in of turn signals and the auxiliary lamp connector Wire Splicing Method This involves tracing the turn signal wires back to where they exit from under the fuel tank This m
2. Turn e 3 Blue Position Running Light in Turn Signal e 4 Blue Position Running Light in Turn Signal e 5 Blue with Pink Stripe Left Turn e 6 Black Ground 2010 amp Earlier Softail 6 place connector on vehicle has the following cavities colors Cavity Color e 1 Black Ground e 2 Brown Right Turn e 3 Blue Position Running Light in Turn Signal e 4 Blue Position Running Light in Turn Signal e Violet Left Turn e 6 Black Ground 2 Cut wiring from each passing lamp and remove acorn nut fastener from both and discard 3 Mount left and right turn signal to mounting bracket 3 using screws 1 lockwasher 2 spacer 4 and locknut 5 Be sure wires exit slot on mounting bracket 2 of 4 isO6671 Screw Lock washer Mounting bracket Lock washer Lock nut SP ONS Figure 3 Turn Signal Mounting is01851 __ a ER me Stripped wire ends in connector 2 Wire ends crimped in connector 3 Connector after heat applied l Figure 4 Installing Sealed Butt Connectors Wire Splicing Method 1 Remove right and left hand turn signals from mirrors and discard 2 Cut wiring from turn signals 3 Cut wiring from each passing lamp and remove acorn nut fastener from both and discard Passing lamp wires will be reconnected using butt splices 4 Mount new left and right turn signal from kit
3. to mounting bracket 3 using screws 1 lockwasher 2 spacer 4 and locknut 5 Be sure wires exit slot on mounting bracket J05209 NOTE The turn signals on international models will have a purple and black wire while domestic will have a purple black and blue wire 5 Make note of the wire colors and positions in each cavity of the six place Multilock socket housing Remove the existing socket housing from the turn signal harness Crimp the terminals on wires using service manual instructions and insert in proper cavities of socket from kit as noted below 2010 amp Earlier Softail 6 place connector on vehicle has the following cavities colors Cavity Color e 1 Black Ground e 2 Brown Right Turn e 3 Blue Position Running Light in Turn Signal e 4 Blue Position Running Light in Turn Signal e 5 Violet Left Turn e 6 Black Ground WARNING Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a e Avoid directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury Avoid directing heat toward any electrical system com ponent other than the connectors on which heat shrink work is being performed Always keep hands away from tool tip area an
4. cMOTOR HARLEY DAVIDSON WB J05209 INSTRUCTIONS REV 2010 07 07 PASSING LAMP TURN SIGNAL RELOCATION KIT GENERAL Kit Number 68412 99A 68413 99A Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required 2011 Softail will require use of an UltraTorch UT 100 Part No HD 39969 Robinair Heat Gun Part No HD 25070 with Heatshrink Attachment Part No HD 41183 or other suitable radiant heating device Crimping tool HD 38125 8 IWIN NIN 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 5 and Table 1 INSTALLATION AWARNING To prevent spray of fuel purge system of high pressure fuel before supply line is disconnected Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00275a Follow service manual instructions to purge the fuel sup
5. d heat shrink attachment Using the UltraTorch UT 100 Robinair Heat Gun or other suitable radiant heating device heat the crimped splice to encapsulate the butt splice connection Apply heat from the center of the crimp out to each end until the meltable sealant exudes out of both ends of the connector Let the splices cool D N Use tie wraps to secure wiring to frame 0 Install fuel tank if previously removed WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 9 Reconnect battery cables positive cable first WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 3of4 10 Test turn signals and passing lamps Align turn signals SERVICE PARTS and passing lamps and tighten hardware isO6677 Figure 5 Service Parts Passing Lamp Turn Signal Relocation Kit Table 1 Service Parts Table Kit Item Description Quantity Part Number Kit 68412 99A 1 Lamp mounting bracket 2 68519 68A Kit 68413 99A 2 Turn signal lamp assembly DOM front 2 68767 94 kit 68412 99A 2 Turn signal lamp assembly DOM front 2 68766 94 kit 68413 99A 3 Mirror mount spacer 2 5714 4 Hel
6. ethod eliminates the need to remove the fuel tank Label the wires according to which turn signal they are routed to Cut the wires leaving approximately 2 3 inches 50 75 mm of wire extending from the point where the wires exit under the tank Relocate Front Turn Signals 1 Disconnect battery cables negative cable first 2 Remove fuel tank using service manual instructions Removing the tank is not necessary if you choose to use the wire splicing method 3 Disconnect the turn signal connector halves under the gas tank J05209 4 Remove connector from turn signal harness and remove turn signals from mirrors Save the internal tooth lock washer spacer and acorn nut 5 See Figure 2 Install the lockwasher and spacer on the mirror shaft and secure with an acorn nut from the kit If the acorn nut bottoms out without tightening remove the acorn nut add a spacer from the kit and install acorn nut and tighten 6 Repeat step 5 for the opposite mirror installation Connector Method 1 Make note of the wire colors and positions in each cavity of the six place Multilock socket housing Remove the existing socket housing from the turn signal harness Crimp the terminals on wires using service manual instructions and insert in proper cavities of socket from kit as noted below 2011 Softail 6 place connector on vehicle has the following cavities colors Cavity Color e 1 Black Ground e 2 Blue with Orange Stripe Right
7. ical spring lock washer nominal screw size 10 4 7069 5 Lock washer internal tooth 2 7127 6 Acorn nut 2 7736 7 Lock nut nylon insert 2 7778 8 Cable strap 6 10181 9 Wire connector butt splice 18 22 GA 8 70585 93 10 Shrink tube 2 72411 97 11 Hex socket cap head screw 4 2647B 12 Socket housing 6 place 73156 96BK 13 Terminal socket 16 20 AWG 73191 96 J05209 4of4
8. ply of high pressure gasoline and remove the fuel supply line if necessary AWARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b J05209 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting Gasoline is extremely flammable and highly explosive which could result in death or serious injury Wipe up spilled fuel immediately and dispose of rags in a suitable manner 00256a 2011 And Later Softail FLSTF 1 See Figure 1 Cut the turn signal wires and conduit flush with the grommet 1 on the underside of the handlebar lower switch housing 2 Remove and discard stock turn signals is06647 Grommet Handlebar lower switch housing Handlebar upper switch housing Turn signal wire vinyl conduit Shrink tube oe ON Figure 1 Cut Turn Signal From Switch Assembly 2 Separate the upper 3 and lower switch housings per service manual instructions 3 Remove the grommet from the end of the turn signal wire vinyl conduit 4 still connected to the switch housing 4 Make about a one inch 25 mm long slit in the end of the conduit Cut one wire back about 1 2 inch 12 mm from the end of the conduit Cut the second wire back about 1 4 inch 6 mm from the end of the conduit

PASSING LAMP/TURN SIGNAL RELOCATION KIT - Harley

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