INSTRUCTIONS - Harley
Contents
1. HARLEY DAVIDSON J01348 INSTRUCTIONS Kit Numbers 77173 99 77174 99 77175 99 77208 99 77209 99 77210 99 77211 99 REV 4 23 99 FLHR CRUISE CONTROL KITS General The kits covered by this Instruction Sheet fit the following models Kit Number Model Fitment 77173799 uio 1996 FLHR 77174 99 1996 FLHRI 77175 99 1994 1995 FLHR 77208 99 1997 FLHR 77209 99 1998 1999 FLHR 77210 99 1997 FLHRI 77211 99 1998 1999 FLHRCI See Service Parts page for kit contents Awarnine Harley Davidson Inc recommends that this kit be installed by a Harley Davidson authorized dealer Improper installation could cause cruise control malfunction loss of control and could result in death or serious injury Service Manual Required This Instruction Sheet refers the installer to the appropriate FLT Service Manual for many procedures Harley Davidson recommends that you do not attempt to install this kit without having a copy of the Service Manual for your vehicle NOTE A Service Manual for your vehicle is available from your Harley Davidson Dealer INSTALLATION Review the CRUISE CONTROL Ultra MODELS section in the Service Manual before attempting to install this kit NOTE When connector numbers such as 22A are referenced they identify connectors on wiring diagrams Wiring diagrams are located at the rear of the FLT Service2. 8 Connect pin connector to wiring harness 9 Reinstall handlebar clamps as described in the appropriate Service Manual Cable Straps 1 See Figures 10 11 and 13 Install cable straps as shown 2 See Figure 14 Attach cruise cable to frame by installing T stud clip with cable strap 1 and place the T stud clip on T stud 3 Check that all wires and harnesses are located away from hot or moving parts Adjust Throttle Idle and Cruise Control Wire Harness 1 Refer to the CRUISE CONTROL THROTTLE CABLES section in Section 8 of the applicable Service Manual and adjust the throttle idle control cable and cruise cables 2 Reinstall saddlebag right side cover and air cleaner assembly 3 Adjust cruise cable last in accordance with the procedure in the applicable Service Manual i00299 Figure 10 Cruise Control Wire Harness Connections at Cruise Module J01348 6 of 15 i00297 Arrow heads show cruise cable routing Cruise control wire harness Cruise disengage switch leads Cable clamp Cable straps Figure 11 Attachment Wire Harness to Frame i01586 eps 1 Black 2 Red Green From Green Indicator Lamp 3 Red to Orange Violet 1 Black to Black From Red Indicator Lamp 2 Red to Red Green Figure 12 Four Place Connector FINAL CHECK AND TEST RIDE WARNING 1 Check that all connections have been made and that all wiring is properly secured with cable
3. Mounting Holes for 1997 FLHR hare ie J _ Q Z Figure 3 Mounting Cruise Module p Instrument Harness Connector 20 Figure 4 J01348 T Connector 33 2 of 15 Relocate the fuse block starter relay brake relay instru ment and ignition switch harness as shown in Figure 4 Connect cruise cable to cruise module and route cable under rear cylinder spark plug wire forward above top engine stabilizer and right to carburetor Follow instruc tions in applicable Service Manual when connecting cruise cable to cruise module and carburetor NOTE Saddlebag sidecover and air cleaner assembly should not be reinstalled at this time 10 11 12 From left side of motorcycle route the cruise cable under rear cylinder spark plug wire forward above top engine stabilizer and then down between cylinder heads and right to induction module Follow Service Manual instructions to connect cruise cable to induction module See Figure 5 Install wire harness retainer on cruise cable and insert barb on clip into hole in frame On Calif mod els remove EVAP hose from cable clip and secure hose with T stud cable strap from kit in location shown Idle Control Cable Throttle Adjusting Screw 1 100998 Remove headlamp following the applicable Service Manual procedures Disconnect stock idle control cable from carburetor follow ing instructions in Service Manual Remove upper and
4. Roll off switch wire connections Figure 8 Throttle Idle Cable and Roll off Switch Configuration Do not adjust throttle and idle cables now The throttle idle and cruise cables will be adjusted after cruise control harness installation See Figure 8 Install the coiled tubing on the throttle cable from front to rear Open the split in the tubing place the tubing on the cable and feed tubing back through the frame clamp until the tubing end contacts the induction module cable guide Cruise Control Wire Harness 1 See Figure 9 Cruise control wire harness electrical con nections See Figure 10 Place cruise control wire harness 1 in position shown Connect 4 place connector 3 cruise control wire harness to accessory harness under seat Connect cruise control wire harness 1 to cruise module 2 17A Route cruise control wire harness 1 to right side of frame and then towards the front See Figure 11 Place cruise control wire harness along right side of frame backbone forward of seat See Figure 8 Position the roll off switch wires as shown and connect the terminals to the switch Splice into pink wire from connector 8 using a sealed butt splice connector 23 See Figure 9 Insert pink wire from cruise harness into empty position in connector 8A Remove instrument console following instructions in the applicable Service Manual Splice the white green wire from the cruise control har ne
5. Set Resume Switch Electrical Connections 1 See Figure 18 Begin Set Resume switch electrical con nections by inserting the wires and terminals 5 on the switch assembly harness into respective cavities of wire seal assembly 2 from kit 4 of 15 8ve To Left Ground Stud under seat Throttle Roll Off Switch on Idle Control Cable Cruise Control Module a b c d e f g h j amp Connector 4A 509 922 00 Indicator Lamps on handlebar clamp Splice to W Grn Speedometer wire under console under seat 1254 To Connector 8A Pin 3 under right side cover Figure 9 Electrical Connections To Handlebar Controls 2 Insert the locking pin 1 with arrow 3 on pin 1 pointing toward the latch cover 4 NOTE If locking pin 1 does not snap into position make sure all pin terminals 5 are fully inserted into the wire seal 2 3 Install the locking pin 1 attachment clip in the dovetail 7 of the kit supplied pin housing 8 4 Connect the two connector halves and attach the attach ment clip to the T stud on the inner side of the outer fair ing bracket Cruise Control ON OFF Switch 1 The accessory switch on the right hand side of the nacelle is used as the cruise control ON OFF switch J Clamp and Throttle Cable 1 See Figure 1
6. straps Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in personal injury 2 Perform the Switch Diagnostic Sequence in the applica ble Service Manual before installing fuel tank outer fair ing left side cover and left saddlebag 3 To perform the tests reconnect battery positive cable first J01348 7 of 15 To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the following proce dures If the battery should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion resulting in death or serious personal injury 3 Cruise cable adjuster 1 Cable strap 2 T stud Figure 14 Cruise Cable Attachment to Frame 4 After tests are completed disconnect battery negative cable first 5 Install fuel tank left side cover headlamp and left saddle bag Awarnine Always connect the positive battery cable first If the posi tive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion resulting in death or serious injury J01348 Steering head i00302 Frame backbone Plastic plug co Figure 15 Remove Plug From Frame 6 Connect batte
7. 5 Using the sharp edge of a knife carefully pull out the plastic plug in forward area of frame 2 Install well nut from kit in hole Install flat washer and J clamp on screw Start screw into well nut With the loop of the clamp orientated at the top tighten the clamp screw until snug 3 Position the throttle control and idle control cables within the J clamp Pinch or press ends of clamp closed to con tain cables Drilling Handlebar Clamp 1 Remove handlebar clamp per instructions in the applica ble Service Manual 2 Using drill template provided at the end of this instruction sheet position on handlebar clamp making sure to align outer edges of template with outer edges of handlebar clamp Use tape to hold in place NOTE Numbers in brackets are connector num bers used in wiring diagrams Cruise control wire harness Cruise control wire harness connection to cruise module 17A Cruise control wire harness connection to main harness 6A Rear fender connector 7 Cruise cable to carburetor 3 Carefully center punch on centers of holes to be drilled 4 Drill 1 16 in pilot holes followed by 5 32 in finished holes 5 Slip lamps into drilled holes red lamp on left green lamp on right AcauTion Do not press on lamp when installing speednut Press only on black housing or lamp may be damaged 6 Place speednuts on indicator lamps 7 Assemble wire leads into four place connector as shown in Figure 12
8. Manual on the wiring diagram wallcharts and in the Electrical Trouble Shooting Manual Cruise Control Module To avoid personal injury do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components Gasoline is extremely flamma ble and highly explosive under certain conditions and may result in death or serious injury Awarnine To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the following proce dures If the battery should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion resulting in death or serious personal injury 1 Remove battery left saddlebag left sidecover fuel tank and air cleaner assembly following instructions in applica ble Service Manual For 1997 1999 Models 2 See Figures 1 and 2 Identify mounting holes for cruise control module on left side of battery box 3 See Service Parts illustration Place grommets 6 through holes shown in Figure 1 or Figure 2 with large diameters on inside of battery box NOTE The cruise cable will be installed on the cruise module in the kit If cable is removed refer to applicable Service Manual for correct reinstallation procedure 4 See Figure 3 While feeding cruise cable and adjuster through hole in frame cross member place cruise module in position shown 5
9. See Service Parts Install three flange nuts to secure cruise module to box Tighten nuts to 9 11 ft lbs Proceed to step 9 on page 1 For 1994 1996 Models 1 Drill cruise module mounting bracket using the template provided in this instruction sheet 2 See Service Parts illustration Remove the three studs from cruise module mounting holes and discard studs Install module mounting bracket 21 onto module with grommets 6 and truss head screws 34 3 Remove the fuse block starter relay and brake relay 4 Remove the ignition switch harness connectors from mounting bracket under left sidecover then remove mounting bracket and discard 5 Drill two holes in battery tray bracket using the template provided in this instruction sheet 6 SeeFigure 3 Place cruise module in position shown The mounting bracket installed in step 2 has the same hole pattern as the old style module shown in Figure 6 7 See Service Parts illustration Secure module mounting bracket in place using washers 15 and screws 7 from kit Tighten screws to 6 ft Ibs 1 of 15 Cruise module mounting holes Left side of battery box Figure 1 Cruise Module Mounting Holes for 1997 FLHRI 1998 1999 FLHR C I 100742 WWF A d t o i Ne 6 Cruise module old style shown Cruise cable RI Connector latch c Cruise connector 17B Cruise module mounting holes Left side of battery box Figure 2 Cruise Module
10. XXXXX FLHR Cruise Control Kits Description Qty Part No Secondary lock 3 place not shown 72143 94 x gt lt 77208 99 x lt 77209 99 x lt 77210 99 x lt 77211 99 Secondary lock 4 place not shown 72144 94 Flange locknut not shown 7716 Set resume switch not shown 77101 90B Pushnuts 2 not shown 7905 Blind rivet not shown 8625 Machine truss screw 933 Truss screw M6 x 1 958 X XK XK lt Xx x 77173 99 XX gt lt gt lt lt lt 0 x 77174 99 lt gt lt gt lt gt lt gt lt gt lt gt lt lt 77175 99 Wire harness retainer not shown 56073 83 Wire harness retainer not shown 70345 84 Flanged locknuts 3 not shown 7499 Nut nylon insert 10 24 4 not shown 7624 J01348 12 of 15 Drill Templates i01416 HANDLEBAR CLAMP TEMPLATE NOTE These marks should measure exactly 1 inch in each direction Please measure to verify that this template is the correct size J01348 13 of 15 101417 FUSE BLOCK TEMPLATE 1 Locate Template using three large holes 2 Drill 2 7 32 diameter holes as shown NOTE These marks should measure exactly 1 inch in each direction Please measure to verify that this template is the correct size J01348 14 of 15 J01348 BRAKE AND STARTER RELAY TEMPLATE 1 Locate template using two large holes 2 Drill 2 7 32 diameter holes as shown NOTE These marks should measure exactly 1 inc
11. h in each direction Please measure to verify that this template is the correct size 15 of 15
12. lower right handlebar switch housing Screws See Figure 7 Loosen throttle adjusting screw 1 and remove friction spring 2 from groove in switch housing 3 T stud for attaching EVAP hose on Calif models Rear cylinder head Figure 5 Attaching Cruise Cable Adjuster Left Side View J01348 10 Remove retaining ring 4 from throttle adjusting screw 1 and remove spring 5 and screw 1 from lower switch housing 3 Plug throttle adjusting screw tapped hole in switch hous ing 3 with pop rivet 6 and washer 7 Discard throttle adjusting screw spring retaining ring and friction spring Remove idle control cable brass ferrule from notch in throttle grip Retain brass ferrule for use later Follow instructions in Section 2 of applicable Service Manual to remove stock idle cable Follow instructions in Section 8 CRUISE CONTROL THROTTLE CABLES of applicable Service Manual and install the new idle control cable from kit 100946 Figure 6 Cruise Control Modules i00295 Throttle adjust screw 4 Retaining ring 5 Spring 6 Pop rivet 7 Washer Friction spring Lower right switch housing Figure 7 Throttle Adjusting Screw and Tapped Hole 3 of 15 100303 11 12 Cruise control harness Q Throttle cable Roll off switch wires inboard of throttle amp idle cables E Coiled tubing 7 Idle cable
13. ry positive cable first 7 Install seat AWARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could result in shifting during vehicle operation loss of control of vehicle death or serious injury 8 Refer to cruise control section in Owner s Manual for cruise control operating instructions 9 Test ride motorcycle and verify cruise control is operating properly 8 of 15 100300 Screw and washer 2 Handlebar clamp 9 Actuator Master cylinder clamp Switch 10 Tabs actuator 2 Master cylinder Tabs wire end of switch 11 Harness Escutcheon Speednut Figure 16 Installing Set Resume Switch Handlebar Clamp i00722a N Stock Washers and Hex Head Screws from kit Set Resume Switch i00293 WIRE COLOR CAVITY White blue A Blue black B Orange violet C Locking pin Pin terminal Wire Seal Socket side for reference only Arrow Attachment clip dovetail Latch cover Pin housing Figure 18 Set Resume Switch Connections J01348 9 of 15 Part No 77173 99 others Date 4 99 SEE e Service Parts FLHR Cruise Control Kits 77127 93C J01348 10 of 15 Part No 77173 99 others Date 4 99 MOTOR e Service Parts FLHR Cruise Control Kits 77173 99 77174 99 77175 99 77208 99 77209 99 77210 99 77211 99 Description Qty Part No J clamp 10003 Cable s
14. ss to the white green wire of the speedometer using the sealed butt splice connector 23 provided in the kit J01348 Set Resume Switch and Cruise Control Wire Harness Placement Into Handlebar Clamp AcauTIon Do not disconnect or remove the switch housing assembly without first placing a 5 32 inch thick cardboard insert or cable strap eyelet between the brake lever and lever bracket Housing removal without an insert may result in damage to the rubber boot and plunger of the front brake light switch 1 See Figure 17 Remove the two screws and washers 1 that secure the master cylinder clamp 2 and master cylinder 3 to the handlebar and remove master cylinder clamp 2 Discard the two screws and retain the washers for use later Remove from the kit and insert the escutcheon 4 into the set resume handlebar clamp 5 Insert switch 6 with side having two tabs 7 positioned as shown Press switch 6 into escutcheon 4 until it latches into position Install speednut 8 place actuator 9 on switch rod and press until actuator pins enter holes in switch tabs 10 Set Resume Switch Attachment to Handlebar Clamp 1 Cut the cable strap securing harnesses to right handlebar Position cruise control harness on handlebar Replace cable strap with one from kit See Figure 16 Attach handlebar clamp to master cylinder with the stock washers and two 1 4 20 x 1 5 8 in hex socket button head screws from kit
15. traps 11 15 inch not shown 10039 Cable straps 3 5 inches not shown 10073 x lt x T stud clip not shown 10133 Retaining rings 2 11193 Grommets 3 11497 Hex capscrews 3 1 4 20 x 5 8 3767B x lt gt x lt x lt gt x lt XxX Xx Xx x Buttonhead screws 2 not shown 4033 eijo j jojo io joj jrm x Handlever clamp not shown 45043 89 Well nut 5207 KM X KK XK OK XK OK OX x lt KL x x x x x a Idle control 56237 99 56228 99 56236 99 Stepper cable 56405 98 56372 97 56372 98 Washer 5 8 x 13 64 x 3 64 6047 Conduit 1 4 in ID x 12 inches not shown 63574 94 Washer 1 4 x 5 8 x 1 16 6703 Washer 10 x 1 2 x 3 64 6716 Washer 6 x 3 8 x 3 64 not shown 6717 Green indicator lamp assembly not shown 68040 99 Red indicator lamp assembly not shown 68161 99 Cruise control harness not shown 70141 99 Cruise module adapter bracket 70183 98 Conduit 133 in ID x 30 inches not shown 70530 89 Sealed butt splice not shown 2 70586 93 Cruise module 70989 98 Pin housing 3 place not shown 72103 94BK Pin housing 4 place not shown 72104 94BK mK KIJKI OK XK OK OK OK KL KK OK Xx x x x x J01348 11 of 15 Part No 77173 99 others Date 4 99 ST e Service Parts SP
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