Auxiliary Light Kit Instruction Sheet - Harley
Contents
1. 1 Strip a 3 8 in 10 mm section of insulation from ends of three ground wires being spliced the two wires from the auxiliary lamps and the ground wire with the ring 2 See Figure 3 Insert two stripped ground wires to butt splice connector 5 3 Insert the end of the ground wire with ring 4 to the opposite end of butt splice 5 Ss amar ae 1 Stripped wire ends inserted in connector 2 Wire ends crimped in connector 3 Connector after heat has been applied is04364 Figure 5 Install Butt Splice Connectors 4 Match color of butt spice connector with cavity of crimping tool Using a Packard Crimping Tool crimp wires into the connector WARNING Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a e Avoid direct heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid direct heat toward any electrical system component other than the connectors on which heat shrink work is being performed e Always keep hands away from tool tip area and heat shrink attachment J05428 a Using Ultra Torch Heat Gun or other suitable radiant heating device heat crimped splice to encapsulate butt splice connection Apply heat from t2. cMOTOR HARLEY DAVIDSON AUA J05428 INSTRUCTIONS REV 2011 03 31 AUXILIARY LIGHT KIT GENERAL Kit Number 68000026 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 Proper installation of this kit requires the following tools which are available at a Harley Davidson dealer e Heat Gun HD 25070 e Packard Crimping Tool HD 38125 8 e Ultra Torch HD 39969 IWIN NIN The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Contents See Figure 6 and Table 1 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 syst
3. d wires from auxiliary lamps 1 into bottom of front fork panel to a location near switch Cover wires to each lamp with vinyl conduit 24 Crimp both gray black wires into one end of a butt splice Use a small section of wire cable 23 and crimp into opposite end of butt splice Crimp final end into spade terminal 22 Attach connector 8 to the nearest terminal on the toggle switch 2 J05428 is04363a Auxiliary lamp 2 Toggle switch Spade terminal Ring terminal Butt splice 2 OT Ee Figure 3 Wiring Diagram 5 See Figure 6 Remove tethered power lead from headlamp wires and attach connector 3 to remaining terminal on toggle switch 2 6 Crimp both black wires into one end of butt splice Use a small section of wire cable 23 crimp into opposite end of butt splice Crimp final end into ring terminal 27 7 See Figure 4 Use the 5 16 inch bolt that attaches upper bracket support for switch panel and grounds the ring ter minal 1 Bolt 5 16 in Figure 4 5 16 Inch Bolt for Ring Terminal Grounding 8 See Figure 1 Attach left side panel 5 to front fork panel 3 under left side of auxiliary lamp bracket 9 Route wires so they are not pinched between the trim panel and fork bracket Use cable straps 25 to secure wires to fork bracket and motorcycle frame 10 Tighten left side bolts on bracket to 19 ft lbs 26 Nm 2of5 Butt Splice Connections
4. em See an authorized Harley Davidson dealer for advice about the amount of current consumed by addi tional electrical accessories or for necessary wiring changes 00211c NOTES Auxiliary fog lamps are not included in this kit The desired style of lamp must be purchased separately HDI motorcycles should only use approved fog lamps J05428 If this lamp kit will be used with a windshield kit refer to the instructions provided with that kit for the correct mounting sequence INSTALLATION Install Auxiliary Lamp and Bracket 1 See Figure 1 Remove and discard two screws 1 and side trim strips 2 from each side of the fork trim panel 3 is04358 Screw 4 Side trim strip Front fork panel TORX screw 2 Back panel left Toggle switch hole location Saf oy Figure 1 Toggle Switch Hole 2 Unfasten TORX screws 4 and remove back panel 5 from front fork trim panel Remove hole plug and discard 3 See Figure 6 Attach adhesive label 1 around drilled hole Figure 1 Item 6 Mount toggle switch 2 in hole using knurled nut 3 Set back panel aside for later wiring 4 Place lockwasher 4 and washer 5 on two bolts 6 Insert bolts through upper holes in bracket 7 and through spacer 8 Thread into upper holes of fork bracket and through trim panel finger tight 5 Place lockwasher 4 and washer 5 on two bolts 9 Insert bolts through lower holes in bracket 7 and t
5. he center of the crimp out to each end until meltable sealant exudes out of both ends of connector Let splices cool D See Figure 6 Install auxiliary lamps 17 and trim rings 19 Final Assembly WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 1 Connect battery cables positive first 2 Install seat according to the instructions in the service manual INN NIN 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 WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 3 Test headlamp high and low beams and the auxiliary lamps for proper operation Refer to HEADLAMP ALIGN MENT in service manual 4 Aim auxiliary lamps and tighten mounting nuts 3 of 5 SERVICE PARTS is04365a Figure 6 Service Parts Auxiliary Light Kit Table 1 Service Parts Table ltem Description Quantity Part Number 1 Label switch 68731 98 2 Switch toggle includes Item 3 knurled nut 67844 70 3 Nut knurled 67846 70 4 L
6. hrough spacer 10 Thread into bottom holes of fork bracket and through trim panel finger tight 6 Tighten right side bolts on bracket to 19 ft lbs 26 Nm 7 Attach auxiliary lamp housing 11 to bracket using hard ware 12 16 in the sequence shown in Figure 6 1 of 5 NOTE The Belleville washer 13 must be positioned cupped side up 8 See Figure 2 Place inner nesting ring on bulb Connect bulb to item 1 connector s is4362a BETA E 1 LED lamp terminal Figure 2 Auxiliary LED Lamp Terminal 9 Attach auxiliary LED lamp 17 and inner nesting ring 18 using outer trim ring 19 screw 20 and nut 21 Auxiliary Lamp Wiring NOTE When wired as follows the auxiliary lamps can only be oper ated while the main headlamp is on low beam This conforms to most state and local laws 1 Remove seat according to the instructions in the service manual 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 2 Disconnect battery cables negative cable first 3 See Figure 3 Route gray black power wires and black groun
7. ockwasher 5 16 in 4 7041 5 Washer flat 5 16 in 4 6330 6 Bolt 5 16 24 x 1 3 8 in 2 4020W 7 Bracket auxilary lamp 12700036 8 Spacer 2 5885 9 Bolt 5 16 24 x 1 in 2 3960W 10 Spacer 2 11827 J05428 40f5 Table 1 Service Parts Table ltem Description Quantity Part Number 11 Housing auxiliary lamp 2 68000033 12 Clamp block auxiliary lamp 2 68720 62 13 Washer Belleville 2 6072 14 Swivel block auxiliary lamp 2 68721 62 15 Washer swivel 2 68693 38 16 Passing lamp nut 2 7892 17 Auxiliary lamp sealed unit 2 Purchased Separately 18 Nesting ring inner 2 68331 02 19 Trim ring outer 2 68725 62A 20 Screw 8 32 x 1 in 2 3514 21 Locknut 8 32 chrome 7606 22 Connector single spade 2 9930 23 Wire cable not shown Not Sold Separately 24 Conduit not shown Not Sold Separately 25 Strap cable 10 10006 26 Connector butt splice 2 70586 93 27 Ring terminal 5 16 inch 9859 J05428 5 of 5
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