INSTRUCTIONS - HARLEY-DAVIDSON Rostock GmbH
Contents
1. install on the fork tube using two button head screws 3 from the kit NOTE Tighten the outer screw first i02292 Tighten first 3 Button head screws 1 Mounting bracket 2 Clamp Figure 1 Install the Mounting Bracket on the Fork Tube Right Hand Side Shown 1 of 6 4 Tighten the screws to 70 80 in lbs 8 9 Nm 5 See Figure 2 Route the lamp wire 1 through the hole in the mounting bracket 2 and secure the lamp 3 to the bracket using a clamp block 4 lockwasher 5 and retainer 6 from the kit Tighten the retainer to 16 18 ft lbs 22 24 Nm 6 See Service Parts illustration Locate the outer trim ring 24 inner nesting ring 27 screw 25 and nut 26 7 See Figure 3 Place the inner nesting ring on the bulb Connect the black wire to the bulb spade terminal next to the bulb indexing tab 1 on the bulb Install the gray wire on the remaining spade terminal 8 Attached the bulb and nesting ring using the trim ring screw and nut identified in step 6 9 Slide the conduit 7 from the kit over the lamp wire 10 Repeat Steps 3 through 9 for the opposite side CAUTION When routing wires along the frame backbone make sure the wires are clear of moving parts heat sources and pinch points to avoid possible short circuits NOTE See Figure 4 for wiring harness component identification 11 See Figure 5 Install the wiring harness Place the relay 1 in the opening in the seat pan and2. route the long leg of the harness 3 along the frame backbone 12 All 2003 and earlier models Cut the connector from the white power lead and replace it with the ring terminal supplied in the kit Connect the white wire with the ring terminal to the copper stud BAT terminal of the main circuit breaker All 2004 and later models Connect the white wire with connector to the B connector on the harness 13 Connect the black ground wire 2 with the ring terminal to the ground stud under the seat or atany good electrical ground point Secure the kit harness to the adjacent harnesses with cable straps Item 16 from the kit i05704 Relay Black wire To vehicle ground Lamp switch White wire To lamps Unterminated wire To headlight yellow low beam wire White wire To battery terminal of main circuit breaker Fuse block Long leg of harness i06452 Wire Mounting bracket Lamp assembly Clamp block Lockwasher Retainer Conduit i Se Bulb index tab 2 Spade terminal 2 g ring index tab 2002 and later Figure 4 Wiring Harness Component Identification J03437 2 of 6 CAUTION When routing wires through the front fork make sure the wires are clear of moving parts to avoid pinching and possible short circuits 14 See Figure 4 Route the harness past the steering head and route the lamp switch 3 leg of the harness alo
3. CM TOR HARLEY DAVIDSON Uy J03437 INSTRUCTIONS REV 8 17 2004 Kit Number 69285 05 CHROME AUXILIARY LAMP KIT General This auxiliary lamp kit fits e All 1993 and later FXDWG models e 1984 and later FXST FXSTB and FXSTC models NOTE Auxiliary fog lamps are not included in this kit The desired style of lamp must be purchased separately HDI International motorcycles should only use approved fog lamps See the Service Parts illustration on the last page of these instructions for kit contents This kit is not compatible with Handlebar Reservoir Cover Sets 46098 98 or 56099 98 due to the location of the switch Models with turn signals mounted on the upper or lower triple clamp will also require Front Directional Relocation Kit Part No 68603 01 available separately at any Harley Davidson Dealer 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 vehi cle electrical system damage See a Harley Davidson Dealer for advice about the amount of current con sumed by additional electrical accessories or for nec essary wiring changes 0021 1b NOTE These lamps require 2 9 amps of available current from the motorcycle s el
4. d result in death or serious injury 00070a 30 Refer to the service manual and follow instructions to install the seat Check for proper headlamp operation before riding motorcycle The automatic headlamp feature provides increased visibility for riders Be sure headlamp is on at all times during motorcycle operation Low visibility of rider can result in death or serious injury 31 Test headlamp high and low beams and the auxiliary lamps for proper operation Aim the auxiliary lamps and tighten the lamp mounting nuts 5 of 6 im Part No 69285 05 Date 8 04 S ervi C e Pa rts Chrome Auxiliary Lamp Kit i06450 crn Description Part No Description Part No Passing lamp housing 2 68276 02 Connector electrical Scotchlok blue 70576 68 Sealed unit purchased separately reference only Clip adhesive backed 4 10102 Bracket lamp mounting right Not sold Cable strap 7 8 in 198 mm 12 10181 Clamp lamp mounting right Not sold Shrink tube 72266 94 Bracket lamp mounting left Not sold Harness retainer 4 70345 84 Clamp lamp mounting left Not sold Bracket switch mounting Not sold Screw socket head Conduit vinyl 15 in 38 1 cm 2 Not sold 1 4 20 x 3 4 in locking 4 927A Wiring harness assembly 69104 04 Clamp block auxiliary lamp 2 68720 62 Ring terminal 9858 Lockwasher internal tooth 3 8 in 2 7130W Switch 70370 00 Retainer lamp mounting 2 Not sold Trim ring 68725 62A Boot swi
5. ectrical system The rider s safety depends upon the correct installation of this kit Use the appropriate service manual proce dures 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 A service manual for your model motorcycle is available from any Harley Davidson Dealer Installation To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00049a 1 Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first Stop the engine when refueling or servicing the fuel sys tem Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002a 2 Remove the fuel tank See FUEL TANK REMOVAL in the applicable service manual 3 See Figure 1 The mounting brackets 1 and clamps 2 are side specific Select the right hand or left hand bracket and clamp and
6. ng the left side of the handlebar to the clutch control 15 See the Service Parts illustration Obtain the switch mounting bracket Item 19 from the kit Unscrew the boot from the lamp switch and install the switch into the bracket Replace the boot on the switch NOTE If the boot becomes worn or damaged or is lost replace the boot to prevent moisture from entering the switch See the Service Parts illustration Item 11 16 See Figure 6 Remove the lower screw 1 and washer from the clutch control clamp and install the lamp switch and bracket assembly 2 Install the screw and washer and tighten to 60 80 in Ibs 7 9 Nm For International Applications Place the fog lamp switch label 3 on the clutch control clamp 17 See the Service Parts illustration Secure the lamp switch leg of the harness to the handlebar using the wire harness retainers Item 18 as needed Snap the retainers into the holes in the handlebar 18 Remove the headlamp assembly See HEADLAMP REMOVAL instructions for the correct model in the ser vice manual NOTE When wired as follows the auxiliary lamps can only be operated while the main headlamp is on low beam This conforms to many state and local laws 19 See Figure 7 Route the unterminated wire 1 from the switch through the grommet into the headlight housing Splice it to the yellow low beam wire 2 using the Scotchlok electrical connector Item 14 from the kit NOTE To route
7. tch 67880 94 Screw 3514 Label lamp switch HDI Nut 7606 international only 68604 01 Inner nesting ring 68331 02 Connector pre insulated sealed butt splice 70586 93 J03437 6 of 6
8. the wire through the grommet push a hooked piece of wire through the grommet from the inside of the headlamp housing Soap the toggle switch wire and pull it back through the grommet with the hooked wire In some applications the wire from the kit harness may not fit through the headlight housing grommet If this is the case splice the black wire to the yellow wire outside the headlight housing then tape the connector to shield it from moisture 20 Install the headlamp assembly See HEADLAMP INSTALLATION instructions for the correct model in the service manual J03437 i02286 1 Relay 2 Ground stud 3 Long leg of harness L Figure 5 Install the Wiring Harness FXDWG Shown i02280 eps 1 Lower clamp screw 2 Lamp switch and bracket assembly 3 Lamp switch label Figure 6 Install the Lamp Switch on the Clutch Control Clamp 1996 and Later Shown i02294b 1 Unterminated wire from lamp switch 2 Yellow low beam wire Figure 7 Splice the Unterminated Wire from the Switch to the Headlight Yellow Low Beam Wire 3 of 6 21 See Figures 8 and 9 and the SEALED BUTT SPLICE CONNECTORS section of the service manual Slide the heat shrink tubing 1 over the white wire 2 from the kit harness and crimp the electrical connector 3 to the wire with a Crimp Tool Part No H D 38125 8 22 Bring both lamp wires 4 to the connector Trim the wires allowing approximately 1 inch 25 mm of the
9. wire to extend past the butt splice connector Trim the conduit 5 approximately 1 1 2 in 88 mm back from the end of the wire 23 Remove approximately 3 8 in 10 mm of insulation from the end of the lamp wires 24 Insert the ends of both lamp wires 4 into the electrical connector 3 and crimp the wires to the connector with the crimp tool 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 NOTE Protect the heat shrink tubing from the heat source while applying heat to the electrical connector 25 Slide the heat shrink tubing 1 away from the splice and using the UltraTorch UT 100 H D 39969 Robinair Heat Gun H D 25070 with Heatshrink Attachment H D 41183 or other suitable radiant heating device heat the crimped splice to encapsulate the butt splice connection Apply heat from the center of the crimp out to each end until the meltable sealant exudes out of both ends of the connector Let the connector cool 26 Slide the heat shrink tubing back over the splice and using the same radiant heating device heat the tubing to encapsulate the butt splice connection Apply heat from the center of the tubing out to each end J03437 i02295 1 Heat shrink tubing 2 White wire from kit harness 3 Butt splice connector 4 Lamp
10. wires 5 Conduit Figure 8 Connect the Lamp Wires to the Kit Harness Siripped wire ends inserted in connector ono Wire ends crimped in connector ANCS Connector after heat has been applied Figure 9 Installing Sealed Butt Splice Connectors 4 of 6 CAUTION When securing the wires to the lower fork steering bracket make sure the wires are clear of moving parts to avoid pinching and possible short circuits 27 Secure the wires to the lower fork steering bracket using the adhesive backed clips Item 15 from the kit Stop the engine when refueling or servicing the fuel sys tem Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002a CAUTION Be sure that wiring harness does not get pinched between fuel tank and frame during tank installation 28 Install the fuel tank See FUEL TANK INSTALLATION in the applicable service manual Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a 29 Connect the battery cables positive cable first J03437 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 coul
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