XL STOP/TAIL/TURN SIGNAL AND LICENSE - Harley
Contents
1. NOTE This instruction sheet refers to service manual information A service manual for this year model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Contents See Figure 5 and Table 1 INSTALLATION Preparation 1 Position the vehicle on a motorcycle lift under the frame so the vehicle is upright and level J04811 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 2 Refer to the service manual and follow the instructions given to remove the main fuse 3 Follow the service manual instructions to remove the seat 4 Raise the rear of the vehicle to relieve the load on the shock absorbers 5 Follow the service manual instructions to remove only the bottom end shock absorber fasteners on each side of the vehicle Save the fasteners for later assembly NOTE Upper end shock absorber fastener removal may be required for installation of specific saddlebags Refer to the instructions found with the saddlebags for further information 6 Raise the rear of the vehicle further to allow access to the underside of the rear fender Electrical Disconnection 1 Unclip the ECM from the electrical caddy per service manual instructions with the following exception a Unplugging the2. With an assistant holding the STT relocation assembly in place insert a screw through the forward mounting hole in the relocation assembly the second rearmost hole in the support cover the spacer the fender support and the mounting hole in the rear fender Install the flange nut onto the screw threads but do not fully tighten at this time Repeat Steps 6 through 8 for the opposite side of the vehicle Tighten all fender mounting hardware in the following sequence a Tighten the screw and seat post to 8 13 ft lbs 10 8 17 6 Nm b If INSTALLING docking points Tighten the forward and rearmost fender support screws with docking points on both sides of the fender to 21 25 ft lbs 28 5 33 9 Nm If NOT INSTALLING docking points Tighten the forward and rearmost fender support screws on both sides of the fender to 11 18 ft lbs 14 9 24 4 Nm c Center the relocation bracket up and down in its range of motion then tighten the relocation bracket screws to 21 25 ft lbs 28 5 33 9 Nm d Align the STT lamps so that the lenses are aimed straight rearward for proper visibility Protect the finish of the black nuts with cloth or paper to prevent damage While holding the lamp housings in position tighten the black left and right jam nuts against the lockwashers to 8 13 ft lbs 14 9 24 4 Nm 5of8 Rear Lamp Wiring Connection to Vehicle 1 Refer to the notes made during the removal steps and insert the license pla
3. 5 16 inch 8 mm nominal ID 2 7042 18 Hex jam nut black 5 16 24 2 Not sold separately 19 Screw hex head 1 4 20 x 7 8 inch 22 mm long 2 3802W 20 Flat washer 1 4 inch 6 4 mm nominal ID 2 6235 21 Reflector rear red 59988 72A 22 Bracket reflector mount left 68857 07 23 Pop rivet 2 8692 24 Housing amp 2 way socket 73152 96BK 25 Housing amp 3 way socket 73153 96BK 26 Housing amp 2 way pin 73102 96BK 27 Housing amp 3 way pin 73103 96BK Items mentioned in text but not included in kit A Original equipment OE license plate illuminator US models only License plate illuminator H D Part No 68183 07 all other models Square hole in license plate bracket Illuminator wire entrance hole in STT relocation weldment tube Y joint right and left in STT relocation weldment tube STT lamp wire entrance hole right and left in relocation weldment tube Forward end of turn signal relocation weldment tube right and left Upper clips 3 on reflector bracket Item 22 IlO nim olol w Lower clips 3 on reflector bracket Item 22 Rear fender cutaway view Wide wire clip right and left on plastic rear fender extension mud flap Wire pass through hole right and left in fender TIAS Left side reflector red H D Part No 69490 07 required for US models only J04811 8of8
4. from the kit 4 Apply a few drops of Loctite 271 Red to the clean screw threads Assemble the license plate bracket to the weldment as shown and tighten the screws to 120 in Ibs 13 6 N m NOTE If using a metal tool to install the black nuts protect the finish with cloth or paper to prevent damage 5 Loosely install the black painted nuts 9 onto the threaded studs on each side of the STT relocation weldment J04811 6 Get the rear reflector 10 from the kit 7 Clean the reflector mounting area of the license bracket with a mixture of 50 70 isopropyl alcohol and 30 50 distilled water Allow to dry thoroughly NOTE Ambient temperature should be at least 60 F 16 for proper adhesion of the reflector to the bracket 8 Remove the liner from the adhesive backing of the reflector Carefully position the reflector centered both horizontally and vertically to the reflector mounting area of the bracket and press firmly into place Hold the reflector in position with steady pressure for about one minute NOTE Allow AT LEAST 24 hours after applying the reflector before exposing the area to vigorous washing strong water spray or extreme weather The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature is06265 License plate illuminator Spacer Illuminator cover Button head screw 2 License plate bracket STT relocation weldment Hex head screw 2 Flat
5. 70 isopropyl alcohol and 30 50 distilled water Allow to dry thoroughly c Remove the liner from the adhesive backing of the reflector Carefully position the reflector centered both horizontally and vertically to the reflector mounting area of the bracket and press firmly into place Hold the reflector in position with steady pres sure for about one minute NOTE Allow AT LEAST 24 hours after applying the reflector before exposing the area to vigorous washing strong water spray or extreme weather The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature 4 Have an assistant raise or lower the fender to the approximate mounted position Tighten the seat post finger tight NOTE On H D Smart Security System equipped vehicles Make sure the antenna harness feeds up between the oil tank and fender on the right side of the vehicle and is not pinched between the fender and the frame crossmember 5 If installing saddlebags or docking points a Get the fender mounting hardware from the saddlebag or docking point kit and install per the instructions in that kit b Proceed to Step 6 4of8 If NOT installing saddlebags or docking points a Get the OE fender mounting hardware removed earlier b Place a washer over the screw threads and install the screws through the forward hole in the fender support cover fender support and fender on each side of the vehicle c Threa
6. washer 2 Black painted nut 2 10 Rear reflector 11 License plate bracket square hole 1 2 3 4 5 6 7 8 9 Figure 1 License Plate Illuminator Installation Rear Lamp Wiring 1 Remove the STT lamps from the rear fender support covers per service manual instructions NOTE If necessary apply a light coat of liquid soap window cleaner or all purpose lubricant to the license plate illuminator wire ends and conduit Use a fish tape or mechanics wire if needed to guide the wires through the tube 20f8 See Figure 1 Feed the license plate illuminator wire con duit through the square hole 11 on the left side of the license plate bracket See Figure 5 Guide the wire and conduit into the hole C in the STT relocation weldment 1 tube and push the wires past the Y joint D on the left side of the tube Get three new terminated wires one black 12 one violet 11 and one blue 10 from the kit Feed the unterminated end of one wire into the left side threaded stud E on the STT relocation weldment Guide the wire into the tube and push the wires past the Y joint Feed the unterminated end of the second wire into the threaded stud favoring the inside of the curve Guide both wires and the license plate illuminator wire conduit into the tube until the second wire gets past the Y joint Feed the unterminated end of the third wire into the threaded stud favoring the inside of the curve Gu
7. ECM wiring harness connector 78B from the ECM is not required Electrical connectors are identified in the service manual by the number and letter within brackets Gently lay the ECM to the left side to expose the four way stop tail turn signal STT connectors 18 and 19 and two way license plate illuminator connector 40 beneath 2 Identify and clearly label the left and right STT harnesses on the vehicle side of the harness connections NOTE Make note of the wire colors and cavity locations before removing the terminals from the socket housings on the lamp Side of the harness connections 3 Remove the wires and socket terminals from the STT socket housings 18B and 19B Remove the wires and socket terminals from the license plate illuminator socket housing 40B Set the socket housings aside for later installation 1 of 8 Please dispose of materials responsibly Rear Fender Lamp and License Bracket Removal NOTE The reflector mounting block is held to the fender with double sided tape Take care during removal to avoid scratching paint 1 Remove the rear reflector and mounting block from the underside of the rear fender Remove any residual adhesive from the underside of the fender 2 Remove the license plate from the vehicle if installed Retain the plate and attaching hardware NOTE Note the location and orientation of rear fender mounting hardware and save for later assembly 3 Refer to t
8. cMOTOR HARLEY DAVIDSON WY J04811 INSTRUCTIONS REV 2015 04 14 XL STOP TAIL TURN SIGNAL AND LICENSE PLATE RELOCATION KIT GENERAL Kit Number 73279 10 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 This kit is needed in order to complete the installation of saddlebag kits on specific model motorcycles See the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only for available saddlebag kits model fitment information and additional part requirements Tools and Supplies Required The help of an assistant will be needed for some removal and installation procedures A terminal pick Snap On TT600 3 or equivalent will aid in the installation of this kit Loctite 271 Threadlocker and Sealant Red H D Part No 99671 97 is required for the proper installation of this kit Electrical Contact Lube H D Part No 99861 02 or equivalent is required for the proper installation of this kit 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
9. d the nuts onto the screws but do not fully tighten at this time d See Figure 3 Make certain that the tab 3 on each nut plate 2 fits into the slot 4 in the fender brace 1 when securing the nut plate with the rearmost fender mounting screw 5 e Place a washer over the screw threads and install the remaining screws through the rearmost hole in the fender support cover fender support and fender on each side of the vehicle f Thread the tabbed nut plate onto the screws and tighten the screws enough to hold the tabs in the fender brace slots AR Rear fender brace Nut plate 2 Tab Slot Mounting screw 2 E a a E is06038 Opr Rear fender support Rear fender Rear fender support cover Reflector mount bracket Tail stop turn signal relocation assembly TORX head screw Spacer Hex flange nut O N D OU Bo es Figure 3 Rear Fender Nut Plate See Figure 4 Get the rear fender support covers 3 removed earlier the STT relocation assembly 5 from the previous section and two 5 16 18 TORX button head screws 6 spacers 7 and hex flange nuts 8 from the kit J04811 10 Figure 4 Rear Fender Assembly On each side of the vehicle position a spacer over the second rearmost hole on the fender support as shown Use a piece of masking or household tape to hold the spacer to the rear fender support 1 Make a hole in the tape for the screw to pass through
10. er Align the lamp housing so that the lens will be aimed rearward and parallel to the ground While holding the housing in position hand tighten the jam nut against the lockwasher 16 Insert the terminal of the new black wire 10 into the cavity in the rear of the reflector 5 until it clicks into place Thread the blue wire 12 and violet wire 11 through the center of the reflector 5 and the spring 7 and insert the button terminals into the correct slots and cavities in the reflector bulb socket 6 17 Assemble the lamp as follows a Insert the spring and bulb socket back into the reflector aligning the tab on the socket with the slot in the reflector b Seat the reflector assembly in the rubber gasket aligning the tab on the reflector with the slot in the gasket c Install the reflector assembly aligning the tab on the reflector with the slot inside the lamp and leaving about 1 2 inches 50 100 mm of wire inside the lamp housing Carefully pull the individual wires at the front opening of the STT weldment to remove excess wire from inside the tube d Using the thumbs of both hands apply even pressure around the outer edge of the reflector assembly until fully seated e Liberally apply electrical contact lubricant H D Part No 99861 02 or equivalent to the contacts in the reflector socket and at the base of the bulb Push in the bulb and rotate clockwise to install f Install the lens to the la
11. he service manual and follow the instructions given to remove and disassemble the rear fender and license plate bracket with the following exceptions a The fender will not be completely removed from the vehicle b Rear wheel elevation and removal is not necessary c ECM caddy and rear fender extension removal are not required The seat post needs only to be loosened not removed 4 Have an assistant raise or lower the fender to allow access to the two rearmost rivets on the left side of the vehicle Drill out the rivets on the left side only to remove the license plate bracket mount assembly NOTE Take care when disengaging the license plate illuminator har ness from the license plate bracket mount and fender 5 Remove the license plate illuminator from the license plate bracket mount assembly Save the illuminator The bracket mount and screws can be discarded License Bracket Assembly 1 See Figure 5 Get the new license plate bracket 5 illu minator cover 6 spacer 8 and two M4 screws 7 from the kit and the license plate illuminator A e Removed from the original equipment OE license plate bracket on US models only e Purchased separately on all other models 2 See Figure 1 Assemble the illuminator 1 spacer 2 and cover 3 to the license plate bracket 5 in the sequence shown and tighten the screws 4 securely 3 Get the STT relocation weldment 6 two screws 7 and two flat washers 8
12. icense lamps for proper operation 6 Install the license plate if present to the vehicle with the attaching hardware from the OE installation 6 of 8 SERVICE PARTS Figure 5 Service Parts XL Rear Stop Tail Turn Signal and License Plate Relocation Kit 70f8 J04811 SERVICE PARTS Table 1 Service Parts Item Description Quantity Part Number 1 Stop tail turn signal STT relocation weldment Not sold separately 2 Screw button head TORX 5 16 18 x 1 5 8 inch 41 mm long 2 3148 3 Spacer washer 0 22 inch 5 6 mm thick 2 5792 4 Flanged hex nut 5 16 18 2 7531 5 Bracket license plate Not sold separately 6 Cover license plate illuminator Not sold separately 7 Hex socket button head cap screw M4 0 7 x 0 31 inch 8 mm long 2 3146M 8 Spacer license plate illuminator Not sold separately 9 Wire harness components turn signal includes items 10 14 Not sold separately 10 e Wire blue 2 Not sold separately 11 e Wire violet 2 Not sold separately 12 e Wire black 2 Not sold separately 13 e Socket terminal 18 22 gauge 6 Not sold separately 14 e Protective tubing Not sold separately 15 Harness extension license plate illuminator Not sold separately 16 Recess cover turn signal housing black 2 68864 10 17 Lockwasher helical spring
13. ide all the wires and conduit into the tube until the first wire end comes out through the left forward opening F of the tube Continue pulling and pushing the wires until all the wire ends are exposed Pull the license plate illuminator wire conduit through the tube until the slack is taken up at the license plate bracket Pull a small amount of slack back as wire relief Use a cable strap not provided to bind the license plate illuminator wire conduit to the STT relocation weldment near hole C J04811 is05961a 79 Housing Lens Bulb Gasket Reflector Bulb socket Spring Unthreaded hole Threaded hole 10 Black wire 11 Violet wire 12 Blue wire 13 Protective tubing 14 Recess cover 15 Lockwasher 16 Jam nut 17 Hole in bulb socket cavity OO NO Ao O a Figure 2 Stop Tail Turn Signal Lamp Right Side Shown 9 See Figure 2 Insert the blade of a small screwdriver into the slot at the bottom of the lens 2 of the left side STT lamp and twist to unsnap the lens from the housing 1 Push the bulb 3 in and rotate counterclockwise to remove Set the lens and bulb aside for later installation NOTE Make note of the cavity location and color of each wire in the reflector bulb socket 6 before removing The violet wire 11 should be closest to the locating tab on the bulb socket New wires from the kit must be installed in the same cavities 10 11 12 Note the locat
14. ion and color of the two wires in the reflector bulb socket 6 Slide the bulb socket and spring 7 from the reflector 5 Remove the wires and button terminals from the bulb socket Insert a right angle pick or a 7 64 3 mm hex key into the bulb socket cavity hooking into the hole 17 Pull the reflector free of the lamp housing Separate the rubber gasket 4 from the reflector or housing Remove the ground terminal and black wire 10 from the back of the reflector Guide the protective tubing 13 with all three wires out of the unthreaded hole 8 in the lamp housing and discard 3 of 8 NOTE Be sure the recess cover lockwasher and jam nut have been installed in the exact orientation and sequence shown before feeding the wiring through the stop tail turn signal housing 13 Place a lockwasher 15 onto the left side threaded stud against the jam nut 16 already installed on the STT relocation weldment Place a black recess cover 14 in the orientation shown onto the stud 14 Insert the wires from the left side threaded stud on the STT relocation weldment through the threaded hole 9 in the lamp housing 1 and the center of the rubber gasket 4 15 Screw the lamp housing onto the stud Be careful that the wires are not twisted or damaged as the weldment stud and lamp are assembled Align the recess cover over the holes and recess in the lamp housing The lockwasher will fit inside the hole in the recess cov
15. mp housing and gently apply thumb pressure until it snaps into place Rotate the lens to position the slot at the bottom of the lamp 18 See Figure 5 Get the protective tubing 14 from the kit and cut into two equal length pieces NOTE If necessary apply a light coat of liquid soap window cleaner or all purpose lubricant to the inside and outside of the pro tective tubing J04811 19 Slide one piece of protective tubing over the three STT lamp wires and into the forward opening F of the STT relocation weldment on each side Continue sliding the tubing over the wires until it reaches at least as far as the Y joint or preferably all the way to the STT lamp housing 20 Repeat steps 4 through 19 for the right side STT lamp Rear Fender Lamp and License Bracket Installation 1 See the Figure 5 top inset Get the left side reflector mounting bracket 22 and pop rivets 23 from the kit Position the bracket to the inside left of the fender aligning the mounting holes with the holes in the fender from the drilled out rivets Refer to the similar bracket on the right side 2 Install the bracket to the fender inserting the pop rivets from the outside of the fender 3 For US models only Ambient temperature should be at least 60 F 16 C for proper adhesion of the reflector to the bracket a Get the rear reflector L purchased separately b Clean the reflector mounting area of the bracket with a mixture of 50
16. res Refer to the notes made during the removal steps and insert the STT socket terminals into the correct cavities of the socket housings J04811 8 Connect the socket housings to the pin housings 18A right and 19A left on the vehicle harness Tuck the connectors and wiring into the area under the seat 9 Install the ECM into the ECM caddy and adjust the wiring to best fit securely and safely under the seat Return to Service NOTE If the upper end shock absorber fasteners were removed for saddlebag installation install them at this time Refer to the instructions found with the saddlebags or in the service manual for further information 1 Follow the service manual instructions to install the bottom shock absorber fasteners on each side of the vehicle 2 Lower the motorcycle lift and allow the vehicle to rest on the jiffy stand 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 3 Follow the service manual instructions to install the seat NOTE Verify that the ignition key switch is in the OFF position before installing the main fuse 4 Refer to the service manual and follow the instructions given to install the main fuse 5 Turn the ignition key switch to IGNITION but do not start the motorcycle Check the tail stop rear turn signal and l
17. te illuminator wiring socket terminals into the correct cavities of the two way socket housing removed earlier See Figure 5 Get the license plate illuminator harness extension 15 pin housings 24 and 25 socket housing 26 and 27 from the kit On 2013 and earlier models connect items 24 and 26 to the ends of the wire harness 15 On 2014 and later models connect items 25 and 27 to the ends of the wire harness 15 Connect the pin housing to the license plate illuminator socket housing On the left side route the license plate illuminator wiring and protective tubing through the three upper clips G on the reflector bracket 22 behind the wide plastic clip J on the plastic rear fender extension mud flap toward the front of the fender and out through the wire pass through hole K in the fender On each side route the STT wires and protective tubing through the three lower clips H on the reflector bracket behind the wide plastic clip and out through the wire pass through hole Route the STT wires and protective tubing over to the four way STT connectors 18A and 19A on the vehicle har ness Allow an extra 2 4 inches 50 100 mm to easily make the connections and cut the unterminated wires and tubing Get the six socket terminals 13 from the kit and the four way socket housings removed from the original wires Follow the instructions in the service manual to crimp the terminals onto the STT wi
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