PREMIUM AIR HORN INSTALLATION KIT - Harley
Contents
1. 13 Refer to the service manual and follow the instructions to install the seat J05464 14 Test the horn for proper operation If the horn output is diminished sounds like a goose reverse the connections at the horn the positive and negative terminals are reversed is01981 r Feed long branch of harness into opening in this 1 area 2 Electrical caddy 3 Vehicle wire harness 4 Tie relay to vehicle wire harness in this area 5 Battery positive terminal Figure 4 Top View of Underseat Area 1996 2005 Dyna _ is01982 1 Left side upper frame 2 Electrical caddy 3 Ground stud 2 Figure 5 Chassis Grounds 1996 2005 Dyna 4 of 6 1 Feed long branch of harness into opening in this area 2 Electrical caddy 3 Battery tray Figure 6 Underseat Area 2006 and Later Dyna J05464 is01984 1 Ground stud 2 2 Rear fender Figure 7 Chassis Grounds 2006 and Later Dyna 5 of 6 SERVICE PARTS is01820b Figure 8 Service Parts Horn Installation Kit Table 1 Service Parts Table Item Description Quantity Part Number Bracket horn mounting 69472 05A 2 Screw mounting bracket 5 16 18 94193 91T 3 Flat washer mounting bracket 6781 4 Hex lock nut with Nylon insert2. 5 16 18 7739 5 Isolator 69471 05 6 Screw isolator 1 4 20 3063 T Flat washer isolator 6220W 8 Wire harness horn 69200346 9 e Fuse blade type 20 Amp 72315 05 10 Cable strap 10 10006 11 Cable strap 4 not shown 10039 Items mentioned in text but not included in kit A Horn Part Number 69423 05 includes item B B e Tube air intake Part Number 59606 05 C Engine strap Items mentioned in text D Mounting block on horn E T stud on isolator F Relay on horn harness J05464 6 of 6
3. For Softail models Obtain the horn wiring harness 8 from the kit See Figure 2 and Figure 3 Feed the long branch of the harness into the space in front of the vehicle battery 2of6 underneath the wire loom shield 1 and under the left side upper frame tube 2 a Bring the long harness branch out from under the frame tube and bring it forward alongside the left side branch of the main wiring harness 4 b Tuck the relay F see Figure 8 on the horn harness under the battery negative cable and under the wires connected to the left side chassis ground 5 Position the relay with the electrical connector toward the rear and downward See Figure 8 Use a cable strap 10 to attach the relay to a harness inboard of the left side upper frame tube if necessary c Bring the short harness branch with the ring terminal and black wire sleeve over to the left side chassis ground and add the ring terminal to the ground wires already present d Bring the harness branch with the ring terminal and red wire sleeve over to the area of the battery positive terminal and tuck the fuse holder into the available space in front of the battery For 1996 through 2005 Dyna models Obtain the horn wiring harness 8 from the kit See Figure 4 Feed the long branch of the harness down into the center of the large opening in the frame 1 inside the loop of the thick vehicle wire harness 3 and forward behind the electri
4. cMOTOR HARLEY DAVIDSON WY J05464 INSTRUCTIONS REV 2011 06 24 PREMIUM AIR HORN INSTALLATION KIT GENERAL Kit Numbers 69000035 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 A Premium Air Horn Part Number 69423 05 is required for proper installation of these kits This item is available from a Harley Davidson Dealer AWARNING 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 Electrical Overload NOTICE It is possible to overload your vehicle s charging system by adding too many electrical accessories If the combined electrical accessories operating at any one time consume more electrical current than the vehicle s charging system can produce the electrical consumption can discharge the battery and cause damage to the vehicle s electrical system See an authorized Harley Davidson dealer for advic
5. cal caddy 2 a See Figure 5 Pull the long branch of the harness out from behind the electrical caddy 2 and forward under the left side upper frame 1 b Position the relay F see Figure 8 on the horn har ness with the electrical connector downward Tuck the relay into the frame opening Use a cable strap from the kit to fasten the relay to the harness at loca tion 4 c See Figure 5 Bring the short harness branch with the ring terminal and black wire sleeve over to the chassis ground studs 3 under the electrical caddy 2 and add the ring terminal to one of studs along with the ground wires already present d See Figure 4 Bring the harness branch with the ring terminal and red wire sleeve over to the area of the battery positive terminal 5 and tuck the fuse holder into the available space For 2006 and later Dyna models Refer to the service manual and follow the instructions given to remove the battery and battery tray from the vehicle J05464 See Figure 8 Obtain the horn wiring harness 8 from the kit a See Figure 6 Feed the long branch of the harness down into the forward area of the large opening in the frame 1 and forward behind the electrical caddy 2 b Pull the long branch of the harness out from behind the electrical caddy and forward under the left side upper frame c See Figure 8 Position the relay F on the horn har ness with the electrical connector downward Tuck th
6. e about the amount of current consumed by addi tional electrical accessories or for necessary wiring changes 00211Cc AWARNING When installing any electrical accessory be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modi fied Exceeding the maximum amperage can lead to elec trical failures which could result in death or serious injury 00310a The Premium Air Horn requires up to 18 Amps additional cur rent from the electrical system when sounding the horn J05464 Kit Contents See Figure 8 and Table 1 REMOVAL WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first Save all seat mounting hardware 2 See Figure 1 Remove the acorn nut 1 and flat washer 2 to free the horn assembly from the rubber mount 3 stud Remove the rubber mount from the weld nut on the engine strap and discard the mount 3 Remove the elbow terminals 4 from t
7. e relay into the frame opening Use a cable strap 10 from the kit to fasten the relay to the harness if necessary d See Figure 7 Bring the short harness branch with the ring terminal and black wire sleeve over to the chassis ground studs 1 forward of the rear fender 2 and add the ring terminal to one of studs along with the ground wires already present e Bring the horn harness branch with the ring terminal and red wire sleeve forward and out from the frame f Refer to the service manual and follow the instructions given to install the battery tray to the vehicle Bring the horn harness ring terminal around the outside front of the battery tray over to the area of the area of the battery positive terminal Tuck the fuse holder into the available space 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 NOTE Fuel tank removal is not necessary to install the Premium Air Horn However the fuel tank must be raised enough to route the wire harness and air intake tube 2 ALL models Refer to Fuel Tank Removal section in the the service manual and follow the steps up to and including removal of the fuel tank attaching hardware Continue the long leg of the horn harness forward to a point directly above the new horn Fasten the horn harness to the existi
8. he two spade con tacts on the horn 9 and release the main harness conduit 5 from the J clamp 6 NOTE DO NOT cut the elbow terminal from the black wire 4 For 2011 and later Softail and 2012 and later Dyna models Cut the elbow terminal from the red violet wire Do not cut the black wire from the horn on the main har ness For All Other Models Cut the elbow terminal from the yellow black wire Do not cut the black wire from the horn on the main harness a Remove the 10 mm flange nut 7 from the circular recess at the back of the horn bracket 8 Remove the horn from the chrome horn cover 10 1 of 6 is01804 Acorn nut Flat washer Rubber horn mount Elbow terminals 2 Main harness J clamp Flange nut Horn bracket Horn 10 Chrome horn cover 11 Speed nut 12 Screw serrated flange OO NO PO Nes New Horn Wiring gt is01978 j 1 Wire loom shield 2 Left side upper frame tube 3 Battery negative cable 4 Main wiring harness left side branch 5 Left side chassis ground 6 Battery positive terminal Figure 2 Battery Compartment Softail Models Figure 1 Original Equipment Horn Removal INSTALLATION 1 See Figure 8 Obtain the horn mounting bracket 1 chrome hex screw 2 and large chrome flat washer 3 from the kit Assemble the bracket to the weld nut on the engine strap C with the bent tab toward the vehicle using the screw and wa
9. ng harnesses rear ward of the horn with cable straps from the kit as needed Continue the horn harness leg down to the horn Plug the elbow terminal of the yellow wire onto the terminal marked positive Plug the elbow terminal on the black wire on the main harness conduit onto the terminal marked negative For 2011 and later Softail and 2012 and later Dyna models Refer to the service manual Connect the red violet wire on the main harness conduit to the butt splice connector on the yellow black wire on the horn harness For All Other Models Refer to the service manual Connect the yellow black wire on the main harness 3of6 conduit to the butt splice connector on the yellow black wire on the horn harness N See Figure 8 Obtain the air intake tube B comes with the Premium Air Horn Push the tube connector into the opening near the bottom of the horn until the tab retainer clicks into place NOTES Position the air intake tube so it will not get pinched by the seat or fuel tank after installation contact hot engine or exhaust components or interfere with the operation of the motorcycle Do not pinch the tube when fastening with cable straps Route the tube upward to the area under the seat Fasten the tube to the motorcycle with cable straps as needed Do not pinch the tube by over tightening the straps Cut off any excess tube or strap length WARNING When servicing the fuel system do no
10. sher Do not fully tighten at this time 2 Obtain the new isolator 5 and hex lock nut 4 from the kit Insert the threaded stud on the isolator from the out side into the large hole in the horn mounting bracket Fit the three pins on the isolator into the small holes in the bracket and fasten the isolator to the bracket with the lock nut Tighten to 80 100 in Ibs 9 0 11 3 Nm NOTE Rotating the bracket will aim the horn forward and down at a 45 degree angle for best sound dispersion 3 Rotate the horn mounting bracket clockwise tight against the engine strap Tighten the chrome hex screw to 80 100 in Ibs 9 0 11 3 Nm 4 Obtain the Premium Air Horn item A purchased separ ately and the socket head screw 6 and small chrome flat washer 7 from this kit Hook the mounting block D on the back of the horn over the T stud E on the isolator Align the hole on the top of the mounting block with the threaded hole in the T stud 5 Fasten the horn to the stud with the screw and washer Tighten to 100 120 in Ibs 11 14 Nm NOTE On the underside of the horn note the small and markings at the terminals For use later but not as readily visible at that point J05464 1 Wire loom shield 2 Left side upper frame tube 3 Battery negative cable and right side chassis ground 4 Main wiring harness left side branch 5 Left side chassis ground Figure 3 Chassis Grounds Softail Models 1
11. t 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 9 Tighten the fuel tank hardware following the instructions in the service manual NOTE To prevent possible damage to the electrical system verify that the ignition light key switch is in the OFF position before connecting the battery cables 10 Verify that the ignition light key switch is in the OFF posi tion IWIN NIN 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 NOTICE Do not over tighten bolts on battery terminals Use recommended torque values Over tightening baitery ter minal bolts could result in damage to battery terminals 00216a 11 Refer to the service manual and follow the instructions given to connect the positive red battery cable and install the horn harness ring terminal with the red wire sleeve to the positive battery terminal 2 Follow the instructions to connect the negative black battery cable to the negative battery terminal 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
Download Pdf Manuals
Related Search