Davidson ® Heated Clothing — Instructions
Contents
1. 3 4 5 1 3000 7 7 9 45 10 2 11 9 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 50 50 50 50 1000 053 2 28 3 03 4 73 1500 16 47 18 22 18 97 20 67 3000 26 36 28 11 28 86 30 56 HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS FXD Motorcycle Family 2007 and Later Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 16 Amps 2 Amps needed to maintain battery charge FX Motorcycle Family 2007 and Later Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 16 Amps 2 Amps needed to maintain battery charge XL Motorcycle Family 2007 and Later Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 16 Amps 2 Amps needed to maintain battery charge Power Required Watts 77 54 44 22 Power Required Watts 77 54 44 22 Power Required Watts 77 54 44 22 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 40 40 40 40 1000 10 41 12 16 12 91 14 61 1500 20 61 22 36 23 112. Watts 77 54 44 22 Alternator Type 22 22 22 22 Available Amps R P M Assumptions Nominal Current Usage 8 Amps 2 Amps needed to maintain battery charge FX Motorcycle Family Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Power Required Watts 77 54 44 22 Available Amps R P M Assumptions Nominal Current Usage 16 Amps 2 Amps needed to maintain battery charge FXD Motorcycle Family 2003 and Earlier Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Power Required Watts 77 54 44 22 Available Amps R P M Assumptions Nominal Current Usage 8 Amps 2 Amps needed to maintain battery charge 1000 3 7 1 95 1 2 0 5 1500 2 1 3 85 4 6 6 3 3000 5 4 7 15 7 9 9 6 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 38 38 38 38 1000 6 1 4 35 3 6 1 9 1500 5 9 7 65 8 4 10 1 3000 12 7 14 45 15 2 16 9 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 32 32 32 32 1000 4 4 2 65 1 9 0 2 1500 6 7 8 45 9 2 10 9 3000 14 0 15 75 16 5 18 2 HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Note The garments may be switched on as long as th
3. 2 Plug the AC power cord into a properly rated AC outlet 110v 3 Plug the chargers output cord into the battery output port 4 The battery power level indicator LED is green when it s fully charged or red if charging is needed 5 Charge the battery until the red LED on the charger is a green color and the number 9 LED on the battery is luminated The battery is now fully charged Power Level Push button Indicators Power Level The BATLI124 battery is equipped with a power level indicator that displays the battery strength in numerical form ranging from 1 to 9 When the level is at the lowest setting 1 it is in serious discharge and needs to be recharged to prevent damage to the battery When the battery is at the highest level 9 it is fully charged When not connected to a product hold down the POWER button to check your power level or battery strength When connected to a product and desired power setting has been selected the power level will be displayed after 5 seconds NOTICE Please read the enclosed warnings carefully before using the BATL124 Li Polymer battery Use the product correctly and according to the procedures described in the manual Save the manual for future reference HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS Model BATLI124 Rating 11 1v 4Ah Output power 11 1v to 12 6v 4 5Amax Output adjusts 1 5 5 is high Input 12 8v 1 5A Capacity Displays 0 9 9 is full C
4. 24 81 3000 27 03 28 78 29 53 31 23 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 40 40 40 40 1000 10 41 12 16 12 91 14 61 1500 20 61 22 36 23 11 24 81 3000 27 03 28 78 29 53 31 23 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 30 30 30 30 1000 0 7 1 05 1 8 3 5 1500 5 72 7 47 8 22 9 92 3000 9 24 10 99 11 74 13 44 HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Limited Warranty When you purchase this Harley Davidson heated garment within the United States and Europe the electrical components of the garment are warranted to be free from factory defects in materials and workmanship for the life of the garment All other components of the garment are warranted to be free from factory defects in materials and workmanship for a period of one 1 year from the date of the rst retail purchase If you have a warranty claim please return the garment together with the original receipt and warranty card within the warranty period to any authorized Harley Davidson dealer for inspection Harley Davidson will repair without charge a heated garment found under normal use to be defective during the warranty period If we determine that a garment covered by the warranty cannot be repaired we will replace the garment Please allow 4 6 weeks for repair or replacement This
5. 4 F 20 C or above 140 F 60 C Do not allow this product to come in contact with water or other liquids If water or other liquids enter the battery interior immediately unplug the product from the battery Continued use of the product may result in re or an electrical shock Disposal Do not place in re or incinerate Do not dispose in refuse Recycle in accordance with local regulations HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS CAUTION Failure to charge the battery prior to use will reduce battery life CHARGE BATTERY REGULARLY It is important to maintain at least 25 of your battery power when not in use Failure to do this will result in performance problems and reduced battery life Be certain to use your battery with products with an amp rating less than the maximum capacity output rating for the battery For instance the Li Polymer battery pack has a maximum capacity output rating of 4 amps and should not be used with heated products that draw more than 4 amps Please check your products amp draw before connecting battery pack Failure to do so can overheat the battery causing damage Prior to Use Before using the BATLI124 it should be fully charged Please follow the instructions below on how to use and maintain your battery Charging and Connecting the BATLI124 To set up the charging process proceed as follows 1 Locate the input cable connector for the charger
6. Female Pant Adapter Yellow S A E connector to coaxial plug 98544 04V Male Pant Adapter Yellow S A E connector to coaxial plug 98545 04V Note Please read all the warnings and cautions that follow for proper usage of your Harley Davidson Heated Clothing WARNING To reduce the risk of burns electric shock and re which could result in death or serious injury the Harley Davidson Heated Clothing must be used in accordance with the following instructions Use the Harley Davidson Heated Clothing on a 12 Volt DC circuit only Use appropriate size fuse for your Harley Davidson Heated Clothing riding gear combinations See 12 Volt Battery Harness Fuse Installation Guide Unplug the Harley Davidson Heated Clothing when not in use Harley Davidson Heated Clothing is not to be used by an invalid sleeping or unconscious person a person with poor blood circulation a paralyzed person or a person with diabetes Do not use the cord as a handle Do not crush the Harley Davidson Heated Clothing and avoid sharp folds Do not wear the Harley Davidson Heated Vest or Jacket directly next to the body These items are designed to be worn with a light shirt underneath Never fold or store Harley Davidson Heated Clothing while plugged into the motorcycle Save these instructions CAUTI
7. 100 power output The default setting is 100 When in use if the batteries LED starts ashing it is time to recharge your battery You can extend your battery s run time if you lower the power level Keep in mind that on the lower level you will get less heat Do not continue using the battery when it is ashing on the lowest level NOTICE Please read the enclosed warnings carefully before using the BAT LI 722 R Li ion battery Use the product correctly and according to the procedures described in the manual Save the manual for future reference BAT LI 722 R Designed with an audio beep to aid in adjusting the battery power level without looking Model BATLI722 R Rating 7 4 volt Capacity 2200 mah Charge Time 3 6 hours
8. 6 WARNING Be certain the Connecting Harness cords are not pinched A pinched cord could result in a re or electrical damage to the motorcycle and or riding gear which could result in death or serious injury 4 Secure the Connecting Harness cords to the motorcycle frame with cable straps Be certain the cords fuse and connector will not be pinched 5 See Figure 3 The Connecting Harness socket should hang out under the left hand side of the seat about 2 to 3 inches 50 75 mm I0552 TIF Figure 3 Connector should hang 2 3in below seat 6 Tighten the battery screws negative side rst then reinstall the seat WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a e Connector should hang 2 3 in below seat HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Connecting Heated Clothing WARNING Harley Davidson Heated Clothing must be used with the provided power switch H D part number 98115 04V or with an available thermostat H D part number 98540 04V or 98541 04 Failure to do so may cause burns which could result in serious injury WARNING If Harley Davidson Heated Clothing will be worn by both rider and passenger install two battery harnesses H D part number 98536 04V to the battery terminals Do not connect clothing for more than on
9. Use the lowest rated fuse that is rated above your calculated total current draw Questions 1 800 646 5916 techsupport gerbing com PRODUCT GLOVES SOCKS JACKET PANTS VEST 2 2 2 2 6 4 4 5 4 2 2 2 2 6 4 4 5 4 per pair per pair each each each PRODUCT GLOVES SOCKS JACKET PANTS VEST 2 2 2 2 6 4 4 5 4 per pair per pair each each each PRODUCT GLOVES SOCKS JACKET PANTS VEST 2 2 2 2 6 4 4 5 4 per pair per pair each each each PRODUCT GLOVES SOCKS JACKET PANTS VEST 2 2 2 2 6 4 4 5 4 per pair per pair each each each PRODUCT GLOVES SOCKS JACKET PANTS VEST 2 2 2 2 6 4 4 5 4 per pair per pair each each each FUSE SET COLOR VIOLET TAN BROWN RED BLUE COLOR VIOLET TAN BROWN RED BLUE COLOR VIOLET TAN BROWN RED BLUE COLOR VIOLET TAN BROWN RED BLUE COLOR VIOLET TAN BROWN RED BLUE COLOR VIOLET TAN BROWN RED BLUE AMP 3 5 7 5 10 15 3 5 7 5 10 15 3 5 7 5 10 15 3 5 7 5 10 15 3 5 7 5 10 15 3 5 7 5 10 15 3 5 7 5 10 15 3 5 7 5 10 15 HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS WARNING Use only the connecting harness supplied with your Harley Davidson Heated Clothing DO NOT use the battery tender harness that may already be installed on your motorcycle Failure to install the positive ring terminal with fuse of the supplied connecting harness to the positive battery terminal could
10. longer it is used and if stored below 4 F 20 C or 100 F 38 C Do not attempt to disassemble the battery unit Do not drop and avoid unnecessary external shock or impact Do not expose the battery to wet conditions If water or other liquids enter battery interior HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS immediately unplug the product from the battery Continued use of product in wet conditions may result in re or electrical shock Do not place battery near a heat source Do not expose the battery to direct ame heat or direct sunlight as the battery may explode Keep out of reach of children Do not allow children to put battery in his her mouth Use gloves as directed cannot be plugged into 12 volt products Do not use any chemical cleaner use dry cloth to clean battery unit Do not try and force the connectors together between battery and charger Check skin frequently when using the gloves to prevent burns Do not wear heated gloves with other heated glove equipment Do not wear while sleeping 1 Battery unit 2 Heating elements Figure 14 Harley Davidson Heated Gloves Figure 14 Harley Davidson Heated Gloves Figure 14 Harley Davidson Heated Gloves Figure 14 Harley Davidson Heated Gloves Heating system provides heat to each nger and thumb as well as the top of the hand 1 Instructions for use Fully charge the Li Ion battery as soon as you open
11. the package Connect the Micro Wire Heating system plug into the DC jack on the battery Push the ON button 1 gt second to switch on Store battery in the pocket inside of the glove when operating Wait 5 minutes after putting the glove on and then re adjust the power level to the right temperature for your hand and weather conditions HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS 2 Temperature setting The battery has a four level push controller at highest level it will reach up to 135 F at a ambient temp of 70 F Push the ON button for 1 second to switch on You can set the temperature in four levels 100 75 50 25 Approximate run time of battery for the 2200 mah battery capacity Power Consumption Run Time Level 1 3 5 watts 25 4 hours Level 2 7 0 watts 50 2 hours Level 3 11 5 watts 75 1 5 hours Level 4 14 watts 100 1 hour 3 Battery unit charging See detailed battery BATLI722 R Product Manual New batteries should be charged until the LED turns green on the charger use the AC DC charger right after you open the box During the charging you can see the charging level The battery can be used up to 500 times fully charged To fully charge the battery it will take at least 3 hours for one battery 6 hours for 2 batteries 4 Storage instructions for the battery Unplug the heat assembly from the battery unit
12. to power a second garment worn by the same person HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS I05548 TIF Figure 7 Harley Davidson Heated Jacket Liner I05548 TIF Figure 7 Harley Davidson Heated Jacket Liner Glove plugs may be stored in convenient pockets when not in use The jacket liner has a short yellow yellow socket terminal labeled Accessory also at the waist which can provide power to an additional garment such as heated socks or the Harley Davidson Heated Pant Liner In addition there are short black socket terminals at the end of each arm which can be used to plug in Harley Davidson Heated Gloves A black plug terminal labeled Glove at the waist provides power to the gloves Connect the black socket terminal from the Dual Control Thermostat to this plug If a Dual Control Thermostat is not used and you opt to use a Power Switch or Portable Thermostat Follow directions below to use a Power Switch or Portable Thermostat to supply power to glove terminals at the sleeves 1 Use Y plug splitter part number 98539 04V 2 Connect the two socket terminals female to both black plug terminal male and the white plug terminal male from the jacket liner 3 Connect the remaining plug terminal male to the white socket terminal on the Power Switch or Portable Thermostat This is needed to supply power to the glove terminals at the sleeves see Figure 10 HARLEY DAVIDSON HEATED
13. use gt 6 months Stop using the battery if unit is damaged or is malfunctioning The battery life will be reduced the longer it is used and if stored below 4 F 20 C or above 100 F 38 C Do not attempt to disassemble the battery unit Do not drop and avoid unnecessary external shock and impact Do not expose battery to humid or wet conditions If water or other liquids enter battery interior immediately unplug the product from the battery Continued use of product in wet conditions may result in re or electrical shock Do not place battery near a heat source Do not expose the battery to direct ame heat or direct sunlight as the battery may explode Keep out of reach of children Do not allow children to put battery in his her mouth Use vest as directed Do not use any chemical cleaner use dry cloth to clean battery unit Do not try and force the connectors together between battery and charger Do not make sharp folds in vest Check skin frequently when using the vest to prevent burns Do not wear heated vest with other torso heating equipment When vest is wet allow to dry before wearing To clean vest remove battery then machine wash and hang dry HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS Do not wear while sleeping Do not use vest if wearing other electronic health equipment 1 Battery unit 2 Heating elements Figure 13 Harley Davidson Heat
14. 95 3 2 1 5 1500 6 5 8 25 9 0 10 7 3000 12 3 14 05 14 8 16 5 HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Fl Carbureted Motorcycle Family Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 14 Amps 2 Amps needed to maintain battery charge VRSC Motorcycle Family Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 21 Amps 2 Amps needed to maintain battery charge FL Motorcycle Family 2007 and Later Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 25 Amps 2 Amps needed to maintain battery charge Power Required Watts 77 54 44 22 Power Required Watts 77 54 44 22 Power Required Watts 77 54 44 22 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 38 38 38 38 1000 4 1 2 35 1 6 0 1 1500 7 9 9 65 10 4 12 1 3000 14 7 16 45 17 2 18 9 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 38 38 38 38 1000 11 1 9 35 8 6 6 9 1500 0 9 2 65
15. CLOTHING INSTRUCTIONS Figure 9 98324 09VM 98351 09VW Jacket Liner and Pants with Dual Control Thermostat Figure 9 98324 09VM 98351 09VW Jacket Liner and Pants with Dual Control Thermostat There are convenient pockets in the jacket liner to store the glove terminals when not in use To connecting harness on battery CIRCUIT 1 JACKET CIRCUIT 2 GLOVES PANTS SOCKS JACKET GLOVES ACCESSORY GLOVES ACCESSORY JACKET CIRCUIT 1 JACKET CIRCUIT 2 GLOVES PANTS SOCKS ACCESSORY PLUG Pants or socks plug into this plug PANTS PLUG LINER POWER PLUG Plugs into thermostat plug to control heat output THEROMSTAT PLUG Plugs into liner power plug THEROMSTAT PLUG Plugs into connecting harness THEROMSTAT PLUG Plugs into glove power plug Figure 9 98324 09VM 98351 09VW Jacket Liner and Pants with Dual Control Thermostat HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Harley Davidson Heated Vest Liner The long white plug terminal at the waist is the garment s power wire Plug the power wire directly into the white socket terminal on the power switch or thermostat The vest liner has a short yellow yellow socket terminal also at the waist which can provide power to an yellow yellow additional garment such as heated gloves heated socks or the Harley Davidson Heated Pant Liner To use the Heated Vest Liner with both the Gloves and Pant Liner the Harley Davidson Y Plug Splitter part numbe
16. HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS General All the 12 volt DC items in the Harley Davidson Heated Clothing line may be used alone or in any combination as long as they do not exceed the maximum amperage allowed by your motorcycle See the last pages of this instruction sheet or the Service Manual for your model motorcycle for more detailed information on amperage Harley Davidson Battery Operated Heated Gloves 98356 09VM 98349 09VW are 7 volt DC and operate with a 7 volt portable battery See Harley Davidson Heated Clothing Battery Operated Instructions section of this booklet for more detailed instructions on use and care Note A Service Manual for your model motorcycle is available from any Harley Davidson dealer The following 12 volt heated clothing items are available from any Harley Davidson Dealer Description Part Number H D Heated Jacket Liner plug in only 98324 09VM 98351 09VW H D Heated Vest Liner plug in only 98325 09VM H D Heated Pant Liner plug in only 98326 09VM H D Heated Gloves plug in only 98323 09VM 98350 09VW Above items each include a Connecting Harness and Power Switch see below Gloves also include a 3 Prong Harness Note To use the Heated Vest Liner with both the Pant Li
17. ON It is possible to overload your motorcycle s charging system by adding too many electrical accessories If your combined electrical accessories operating at any one time consume more electrical current than your vehicle s charging system can produce the electrical consumption can discharge the battery and cause vehicle electrical system damage See a Harley Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes 00211a Note See Section 8 of the Service Manual for additional information on testing for voltage output and amperage draw HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS I0554 TIF Figure 1 Connector Types S A E Connector Coaxial Connector Coaxial Socket 12 Volt Battery Harness Fuse Installation Guide WARNING Heated riding gear must be used in accordance with the manufacturer s speci cations and instructions Use a fuse rated for the riding gear combination selected Using a higher heated fuse than required by the riding gear combination selected can fail to protect the circuit which could result in a re causing possible death or serious injury or damage to the riding gear and motorcycle NOTICE Using a lower rated fuse than speci ed can result in the fuse blowing and the product not working as designed Follow included chart for the recommended size fuse for your application Depending on pa
18. R WARRANTIES EXPRESS OR IMPLIED INCLUDING THOSE OF FITNESS FOR A PARTICULAR PURPOSE AND MERCANTABILITY GERBING S HEATED CLOTHING INC SHALL NOT BE LIABLE FOR ANY DAMAGES DIRECTLY OR INDIRECTLY RELATED TO GERBING S HEATED PRODUCTS INCLUDING WITHOUT LIMITATION ANY DAMAGES FOR INJURY TO PERSONS OR PROPERTY OCCURRING WHILE ANYONE IS WEARING GERBING S HEATED PRODUCT WITHOUT LIMITING THE FOREGOING GERBING S HEATED CLOTHING INC SHALL NOT BE LIABALE FOR LOSS OF USE INCONVENIENCE LOST TIME COMMERCIAL LOSS OR OTHER INCIDENTAL OR CONSQUENTIAL DAMAGES THE FOREGOING LIMITATIONS OF LIABAILITY SHALL APPLY TO THE FULL EXTENT PERMITTED BY LAW Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above limitations and exclusions may not apply to you This warranty gives you speci c legal rights and you may have other rights which vary from jurisdiction to jurisdiction Please retain this portion for your records Register online at www gerbing com or ll out information requested below and send postal Harley Davidson Battery Operated Heated Vest Battery BATLI124 WARNING Do not place this near an external heat source or expose the battery to direct ame or heat as the battery may explode which could result in serious injury or death Do not attempt to disassemble or alter any part of this product Do not store below
19. and store battery in a dry area Recharge the battery before use if battery has been sitting unused for a long period of time Avoid storing in direct sunlight Do not store in a humid area Warranty and Registration Information When you purchase this H D product within the United States all the components of the product are warranted to be free from factory defects in materials and workmanship for 90 days from the date of this initial purchase If you have a warranty claim please return the product together with the original receipt to Gerbing s Heated Clothing for inspection Gerbing s will repair without charge a product found under normal use to be defective during the warranty period If we determine that the product covered by the warranty cannot be repaired we will replace the product Please allow 4 5 weeks for repair or replacement Shipping costs are the responsibility of the customer This limited warranty sets forth the complete liability and obligations of Gerbing s Heated Clothing Inc for breach of warranty HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS This limited warranty does not cover repairs by the third parties rips scratches tears cracks and wrinkles from abnormal use and tear or exposure or deterioration caused by ordinary wear and tear or exposure It also does not cover damage caused by accident abuse or improper cleaning or care THIS WARRANTY IS IN LIEU OF ANY AND ALL OTHE
20. ckaging your provided battery harness may not come with a pre installed fuse View the chart and choose the correct size fuse for your clothing combination If your harness came with a fuse installed you will need to take note what size it is Review the chart and replace the installed fuse with the correct size for your clothing combination When you add or change the combination of items check the fuse requirements and change as needed Keep this chart for future reference I0554 TIF Figure 1 Connector Types S A E Connector Coaxial Connector Coaxial Socket HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Connecting Harness Installation WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable rst before proceeding WARNING Disconnect negative battery cable rst 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 00049a 1 Refer to the SEAT and BATTERY sections of your Owner s or Service Manual Remove the seat and disconnect the battery cables negative cable rst PRODUCT GLOVES SOCKS JACKET PANTS VEST AMP DRAW 2 2 2 2 6 4 4 5 4 2 2 2 2 6 4 4 5 4 per pair per pair each each each Example Gloves 2 2 amps Jacket 6 4 amps 8 6 amps Fuse required 10 amp
21. e connector at style connector at waist Y plug splitter has a coaxial plug at Y plug splitter has a coaxial plug at one end and two coaxial sockets at the one end and two coaxial sockets at the other end to connect vest liner pant other end to connect vest liner pant liner and gloves when worn together liner and gloves when worn together White controller adapter has S A E connector at one end and coaxial socket at the other end Single control thermostat connects between battery harness and garment to switch on and o and regulate temperature Red plug to battery connect harness Black female pant adapter has S A E connector at one female pant adapter has S A E connector at one end and coaxial plug at the other end end and coaxial plug at the other end HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS CAUTION It is possible to overload your motorcycle s charging system by adding too many electrical accessories If your combined electrical accessories operating at any one time consume more electrical current than your vehicle s charging system can produce the electrical consumption can discharge the battery and cause vehicle electrical system damage See Harley Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes 00211a Note See Section 8 of the Service Manual for additional information on testing fo
22. e engine speeds indicated in the following charts are maintained See the Typical Charging System Maximum Output Chart Figure 10 and the Family Chart speci c to your motorcycle Note Be aware that other electrical loads such as lamps may already be present These loads will reduce the amperage available for the heated garments and the recommendations must be modi ed accordingly Remember you must add up the amperage draw and battery requirements of ALL electrical items in use FXD Motorcycle Family 2004 and Later Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 16 Amps 2 Amps needed to maintain battery charge FL EFI Motorcycle Family Recommendation Ok above 1500 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Available Amps R P M Assumptions Nominal Current Usage 2 5 Amps 2 Amps needed to maintain battery charge Power Required Watts 77 54 44 22 Power Required Watts 77 54 44 22 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 38 38 38 38 1000 6 1 4 35 3 6 1 9 1500 5 9 7 65 8 4 10 1 3000 12 7 14 45 15 2 16 9 Load Current Amps 5 9 4 15 3 4 1 7 Alternator Type 45 45 45 45 1000 5 7 3
23. e person to a single red socket terminal power switch or thermostat Heated Clothing cords could become entangled distracting the rider which could result in death or serious injury CAUTION Unplug the power cord before getting off the motorcycle Attempting to get off the motorcycle with the clothing still connected may result in minor or moderate injury CAUTION Do not plug the power wire into the short plugs located at the waist of the vest liner or at the waist and arms of the jacket liner These short plugs are intended only to plug in additional garments Plugging the power wire into the short plugs may cause damage to the garments 1 Plug the red plug terminal on the standard power switch see Figure 4 or optional thermostat Figures 5 or 6 into the red socket terminal from the connecting harness If the thermostat is not plugged in correctly it will not work The latest version of the thermostat controller comes with a leather clip case There are no Velcro strips provided Plug the the connecting harness socket terminal directly to the power I05545 TIF Figure 4 Power Switch 98115 04V Supplied with each garment HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS I05545 TIF Figure 5 Optional Portable Thermostat 98540 04V I05545 TIF Figure 5 Optional Portable Thermostat 98540 04V I05547 TIF Figure 6 Optional Dual Control Thermostat 98541 04V Plug the red plug terminal into plug terminal into the conn
24. ecting harness the connecting harness Plug the red terminal into the connecting harness terminal into the connecting harness I05547 TIF Figure 6 Optional Dual Control Thermostat 98541 04V 2 The white socket terminal at the other end of the power switch or optional thermostat and the black socket terminal on the Dual Control Thermostat connects directly to the power wire on Harley Davidson Heated Clothing as follows Harley Davidson Heated Jacket Liner See Figure 7 The long white plug terminal at the waist is the garment s power wire Plug the power wire directly into the white socket terminal on the power switch or thermostat Plug the white socket terminal directly socket terminal directly to the power wire on the Harley to the power wire on the Harley Davidson Heated Clothing Davidson Heated Clothing Plug the white socket terminal directly socket terminal directly to the power wire on the Harley to the power wire on the Harley Davidson Heated Clothing Davidson Heated Clothing To provide power to the gloves plug the To provide power to the gloves plug the black socket terminal directly to the socket terminal directly to the black socket terminal directly to the black black plug terminal on the jacket liner worn by plug terminal on the jacket liner worn by the same person You can also use the the same person You can also use the black socket terminal to power a second garment socket terminal
25. ed Vest Liner Figure 13 Harley Davidson Heated Vest Liner 1 Instructions for using the portable battery Fully charge the Li Polymer battery as soon as you open the package Feed the controller leads thru rubber grommet inside left pocket Connect the Nano Wire Heating pad system by plugging into the DC plug from the vest into the mini controller plug Plug the controller into the battery to set the temperature level by pushing the ON button and again up to two more times for max heat Store battery in the pocket inside of the vest Wait 5 minutes after putting the vest on and then re adjust the power level to the right temperature for body and weather conditions 2 Instructions for using the motorcycle battery Remove plug from portable battery Feed the plug thru opening at bottom of inside left pocket Plug the controller into the bike s connecting harness an extension may be needed to reach bike Set the temperature level by pushing the ON button and again up to two more times for max heat Wait 5 minutes after putting vest on and then re adjust the power level to the right temperature for your body and weather conditions HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS 3 Temperature setting The controller unit has three temperature levels for heating 1 86 F 2 104 F 3 122 F Push the ON button for 1 second to switch on You can set the temperatu
26. g s Heated Clothing Inc Attn Warranty Department 1145 85th Ave SE Tumwater WA 98501 Phone 800 646 5916 Europe Gerbing s Heated Clothing Inc Attn Warranty Department Graaf van Lijndenlaan 3 7316 EG Apeldoorn The Netherlands Tel 31 555 788 788 Fax 31 555 785 104 Email info gerbing nl Internet www gerbing nl HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS Harley Davidson Battery Operated Heated Gloves 98356 09VM 98349 09VW are a 7 volt DC and operate with a 7 volt portable battery See Harley Davidson Heated Clothing Battery Operated Instructions section of this booklet for more detailed instructions on use and care The following battery operated heated clothing items are available from any Harley Davidson Dealer Description Part Number H D Battery Operated Heated Vest Liner 12 volt 98355 09VM H D Battery Operated Heated Gloves 7 volt 98356 09VM 98349 09VW H D Battery Operated Heated Vest 12 volt Battery 98547 09V H D Battery Operated Heated Gloves 7 volt Battery 98548 09V Note Please read all the warnings and cautions that follow for proper usage of your Harley Davidson Heated Clothing H D Battery Operated Heated Vest Liner CAUTION Only use the charger provided otherwise it may cause a re Recharge battery after extended periods of non
27. harge Time 4 6 hours Harley Davidson Battered Operated Heated Gloves Battery BAT LI 722 R WARNING Do not place this near an external heat source or expose the battery to direct ame or heat as the battery may explode which could result in serious injury or death Do not attempt to disassemble or alter any part of this product Do not store below 4 F 20 C or above 140 F 60 C Do not allow this product to come in contact with water or other liquids If water or other liquids enter the battery interior immediately unplug the product from the battery Continued use of the product may result in re or an electrical shock Disposal Do not place in re or incinerate Do not dispose in refuse Recycle in accordance with local regulations CAUTION Failure to charge battery prior to use will reduce battery life CHARGE BATTERY FULLY It is important to maintain at least 25 of your battery power when not in use Failure to do this will result in performance problems and reduced battery life Be certain to use your battery with products with an amp rating less than the maximum capacity output rating for the battery For instance the Li ion battery pack has a maximum capacity output rating of 2 amps and should not be used with heated products that draw more than 2 amps Please check your products amp draw before connecting the battery pack Failure to do so can overheat the battery causing damage Pr
28. ior to use Before using the BATLI722 R it should be fully charged Please follow the instructions below on how to use and maintain your battery HARLEY DAVIDSON HEATED CLOTHING BATTERY OPERATED INSTRUCTIONS Charging the BATLI722 R To set up charging process proceed as follows 1 Locate the charger s case with the 110v input prongs 2 Plug the charger into a properly rated AC outlet 110v 3 Plug the charger output cable s into the batteries charging ports 4 The charger s LED indicator is green when it s fully charged or red if charging is needed 5 Charge battery until the red LED on the charger is a green color and all four LED s on the battery are illuminated The battery is now fully charged Power Setting Push button and indicators The BATLI722 R battery packs are equipped with a POWER button that has two separate functions One is to allow you to check the remaining power or charge in the battery pack and the other allows you to change your power level setting or output The Power Level push button indicator can only be activated when not connected to a product The battery s LED lights will display the battery s current power level from 25 to 100 100 indicates a full charge Push and hold POWER button to check battery strength The Power Setting push button indicator can only be activated while connected to a product Push and hold POWER button to select your desired setting from 25 to
29. limited warranty sets forth the complete liability and obligations of Harley Davidson Motor Company for breach of warranty This limited warranty does not cover repairs by third parties rips scratches tears cracks and wrinkles from abnormal use and tear or exposure or deterioration caused by ordinary wear and tear or exposure It also does not cover damage caused by accident abuse or improper cleaning or care This warranty is in lieu of any and all other warranties express or implied including those of tness for a particular purpose and merchantability Harley Davidson shall not be liable for any damages directly or indirectly related to Harley Davidson heated garments including without limitation any damages for injury to persons or property occurring while anyone is wearing a Harley Davidson heated garment Without limiting the foregoing Harley Davidson shall not be liable for loss of use inconvenience lost time commercial loss or other incidental or consequential damages The foregoing limitations of liability shall apply to the full extent permitted by law Some states or countries do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above limitations and exclusions may not apply to you This warranty gives you speci c legal rights and you may have other rights which vary from jurisdiction to jurisdiction U S A Gerbin
30. ner and Gloves and to use the Portable Thermostat or Power Switch with the Jacket Liner and to power the Gloves at the same time it will be necessary to purchase the Y Plug Splitter part number 98539 04V available at any Harley Davidson Dealer The following accessories and replacement parts may be purchased separately from any Harley Davidson Dealer Description Part Number Connecting Harness battery to controller 98536 04V Power Switch on off switch 98115 04V Portable Thermostat to regulate temperature 98540 04V Dual Control Thermostat regulates two garments 98541 04V 3 Prong Harness for gloves alone 98537 04V Y plug splitter for two garments plus gloves 98539 04V Note The items above all have coaxial connectors In order to use previously purchased Harley Davidson heated garments having S A E plugs with these items one or more of the following adapters may be necessary These adapters can be purchased from any Harley Davidson Dealer HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Description Part Number Controller Adapter White S A E connector to coaxial socket 98543 04V
31. r 98539 04V available at any Harley Davidson Dealer must be used Connect the plug of the splitter into the yellow yellow socket terminal at the waist of the vest and the two plugs of the splitter for the gloves and pant liner Harley Davidson Heated Pant Liner The yellow yellow plug terminal at the waistband is the garment s power wire Plug the power wire directly into the white socket terminal on the power switch or thermostat If the Pant Liner is worn with either the Harley Davidson Heated Jacket Liner or Vest Liner the pants may be plugged directly into the yellow yellow socket terminal located at the waist of the jacket or vest yellow yellow The pant liners also have short plugs at the end of each leg which are to be used to plug in heated socks There are convenient pockets to store the pant leg plugs when not in use Harley Davidson Heated Gloves See Figure 8 When used with the Harley Davidson Heated Jacket Liner the gloves may be plugged directly into the plugs at the end of each arm I05551 TIF Figure 8 Harley Davidson Heated Glove I05551 TIF Figure 8 Harley Davidson Heated Glove Gloves may be plugged directly into the black socket terminals provided on the Harley Davidson Heated Jacket Liner or the 3 Prong Harness provided with the gloves if worn without the jacket When used without the jacket liner plug the 3 Prong Harness H D part number 98537 04 included with the gloves directly into
32. r voltage output and amperage draw Average Amperage Draw Per Item Item Wattage With a 12 volt battery Jacket Liner 77 Watts 6 00 Amps cold Vest Liner 54 Watts 3 87 Amps cold Pant Liner 44 Watts 3 87 Amps cold Gloves 22 Watts 2 28 Amps cold CAUTION Do not switch on the Harley Davidson Heated Clothing if the motorcycle engine is turned off or running below the indicated engine speed or damage to the garments and electrical system may occur Note The garments may be switched on as long as the engine speeds indicated in the following charts are maintained See the Typical Charging System Maximum Output Chart Figure 12 and the Family Chart speci c to your motorcycle Note Be aware that other electrical loads such as lamps may already be present These loads will reduce the amperage available for the heated garments and the recommendations must be modi ed accordingly Remember you must add up the amperage draw and battery requirements of all electrical items in use HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Figure 12 Typical Charging System Maximum Output Figure 12 Typical Charging System Maximum Output HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Load Current Amps 5 9 4 15 3 4 1 7 XL Motorcycle Family Recommendation Ok above 1500 R P M OK at 1000 R P M Garment Type Jacket Liner Vest Liner Pants Liner Gloves Power Required
33. re in three levels color changing LED indicator After 8 seconds you can see the actual battery capacity 9 0 9 fully charged 0 discharged Approximate run time of battery for the 4000 mah battery capacity Level 1 3 hours Green LED Level 2 1 5 hours Yellow LED Level 3 1 hour Red LED 4 Battery unit charging See Battery BATLI124 Product Manual New batteries should be charged until the LED turns green on the charger Use only the provided AC DC charger Charge battery right after you open the box During the charging the battery will indicate charging status The battery can be used up to 700 times fully charged To fully charge the battery it will take at least 4 hours 5 Storage instructions for the battery Unplug the vest from the battery unit and store battery in a dry area Recharge the battery before use if battery has been sitting unused for a long period of time 6 Vest cleaning Vest is machine washable hang dry Use dry cloth to clean the heating system Remove battery and controller before washing H D Battery Operated Heated Gloves CAUTION Only use the charger provided otherwise it may cause a re Recharge battery after extended periods of non use gt 6 months Stop using the battery if the unit is damaged or is malfunctioning The battery life will be reduced the
34. result in burns electrical shock and re which could result in death or serious injury WARNING Connect positive battery cable rst 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 2 See Figure 2 Install the positive ring terminal of the connecting harness to the battery as follows a Place the positive ring terminal from the connecting harness the cord with the fuse onto the positive battery screw b Place the positive battery cable ring terminal onto the screw threads c Reattach the screw to the positive battery terminal but do not tighten at this time see step 6 I04440 TIF Figure 2 Positive and Negative Battery Terminals Negative Battery Terminal I04440 TIF Figure 2 Positive and Negative Battery Terminals Fuse on Positive Wire Positive Battery Terminal Bolt Positive Ring Terminal Bolt Negative Ring Terminal HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS 3 Install the negative ring terminal of the connecting harness to the battery as follows a Place the negative ring terminal from the connecting harness the cord without the fuse onto the negative battery screw b Place the negative battery cable ring terminal onto the screw threads c Reattach the screw to the negative battery terminal but do not tighten at this time see step
35. the white socket terminal on the power switch or thermostat The harness is long enough so that the cords can run up inside a shirt or jacket and extend down the sleeves to plug into the gloves HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Connecting Multiple Garments The following illustrations show some typical garment combinations and the correct connection methods to use Figure 10 98324 09VM 98351 09VW Jacket Liner with Single Control Thermostat Power Switch Figure 10 98324 09VM 98351 09VW Jacket Liner with Single Control Thermostat Power Switch CIRCUIT 1 JACKET CIRCUIT 2 GLOVES PANTS SOCKS JACKET GLOVES ACCESSORY GLOVES ACCESSORY JACKET CIRCUIT 1 JACKET CIRCUIT 2 GLOVES PANTS SOCKS ACCESSORY PLUG Pants or socks plug into this plug LINER POWER PLUG Plugs into thermostat plug to control heat output Figure 10 98324 09VM 98351 09VW Jacket Liner with Single Control Thermostat Power Switch To connecting harness on battery THEROMSTAT PLUG Plugs into splitter THEROMSTAT PLUG Plugs into connecting harness Plugs into splitter plug to control heat output GLOVE ACCESSORY POWER PLUG SPLITTER 98539 04V CIRCUIT 1 JACKET CIRCUIT 2 GLOVES PANTS SOCKS JACKET GLOVES ACCESSORY GLOVES ACCESSORY JACKET CIRCUIT 1 JACKET CIRCUIT 2 GLOVES PANTS SOCKS ACCESSORY PLUG Pants or socks plug into this plug LINER POWER PLUG Plugs into thermostat plug to control heat outp
36. ut Figure 10 98324 09VM 98351 09VW Jacket Liner with Single Control Thermostat Power Switch To connecting harness on battery THEROMSTAT PLUG Plugs into splitter THEROMSTAT PLUG Plugs into connecting harness Plugs into splitter plug to control heat output GLOVE ACCESSORY POWER PLUG SPLITTER 98539 04V HARLEY DAVIDSON HEATED CLOTHING INSTRUCTIONS Guidelines Use only the harnesses switches and thermostats provided with or sold speci cally for use with your Harley Davidson Heated Clothing For maximum liner warmth keep the wind off of your Harley Davidson Heated Jacket Vest or Pant Liners Your heated liner should be worn under windproof clothing Wear only one layer of clothing under your Harley Davidson Heated Clothing A cotton or silk turtleneck under your heated vest or jacket liner is ideal If your Harley Davidson Heated Clothing does not heat check all connections for tightness and wires for proper routing and connection Also check the fuse on the connecting harness If the thermostat does not operate check to be sure it is plugged in correctly per instructions in Step 1 I05555 TIF Figure 11 Old Vest to New Pant Liner with Single Control Thermostat I05555 TIF Figure 11 Old Vest to New Pant Liner with Single Control Thermostat New pant liner with coaxial New pant liner with coaxial connector at waistband connector at waistband Old Vest with S A E Old Vest with S A E styl
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