INSTRUCTIONS - HARLEY-DAVIDSON Rostock GmbH
Contents
1. Tighten the left and right rigid fork socket head screws securely J03497 i06817 1992 and Earlier 1993 and Later 3 Horn bracket Windshield bracket Lamp support bracket Spacer Upper shock mount Figure 2 Support Windshield and Horn Combination i06818 1992 and Earlier 1993 and Later gt A y l 2 4 2 2 Horn bracket 09 2 3 mm spacer from horn kit Lamp support bracket Upper shock mount Spacer Figure 3 Auxiliary Lamps and Horn Combination 1992 and Earlier 1993 and Later Windshield bracket Lamp support bracket Spacer Upper shock mount Figure 4 Auxiliary Lamps and Windshield Combination 2 of 8 Install and Wire the Auxiliary Lamp Housings 1 10 See Figure 5 With the open end facing the rear of the motorcycle fit the U clamp 1 around the support bracket 2 and assemble the lamp housing to the bracket a Hold the U clamp and fit the bevel washers 3 to the curve of the support bracket b With the convex side of the Belleville washer 4 facing the lamp housing thread the gray black GR Bk wire 5 from the housing through the Belleville washer and then through the clamp and the 2 bevel washers c Fit the housing threaded stud 6 through the Belleville washer the U clamp and the bevel washers d Slip a washer 7 over the wire and housing stud and secure with the chrome acorn nut 8 See the Service Parts illus2. 10 Spacer 0 09 2 3 mm thick 2 11 Screw hex socket button head 5 16 24 x 7 8 12 Lockwasher 5 16 inch internal tooth 2 13 Cable strap 7 5 190 mm 4 14 Cable strap 5 5 140 mm 2 15 Butt splice connector blue 3 16 Harness retainer 2 17 Conduit black vinyl 18 46 M 18 Bezel trim ring 2 19 20 Screw 2 Nut 2 21 Inner nesting ring 2 22 Shrink tube 23 Ring terminal pre insulated 24 Switch boot 25 Switch bracket 26 Acorn nut 2 27 Lamp switch label HDI 28 Switch 68683 02 69104 04 6072 58114 88 58115 88 6333 68781 88A 68796 88 4032A 5791 4387 7127 10006 10065 70586 93 70345 84 not sold 68725 62A 3514 7606 68331 02 72266 94 9858 67880 94 Not sold 7892 Not sold 70370 00 J03497 8of8
3. CM TDR HARLEY DAVIDSON VY J03497 INSTRUCTIONS REV 10 01 2004 Kit Number 69286 05A SPRINGER AUXILIARY LAMP KIT General NOTE Auxiliary fog lamps are not included in this kit The lamps must be purchased separately HDI International motorcycles should only use approved fog lamps These kits are not compatible with Handlebar Reservoir Cover Sets 46098 98 or 46099 98 See the Service Parts illustration for kit contents CAUTION When installing any electrical accessory be certain not to exceed the maximum amperage rating of the fuse or cir cuit breaker protecting the affected circuit being modified Exceeding the maximum amperage can lead to electrical failures which could result in death or serious injury 00310b AwarninG The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabili ties 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 00308a NOTE This instruction sheet references service manual information A service manual for the year and model motorcycle is required for this installation and is available from a Harley Davidson dealer Installation Prepare the Motorcycle for Service 1 For EFI models Follow the Service Manual instruc tions to purge the fuel supply of high pressure gasoline and remove the fuel sup
4. e 3 8 16 x 2 1 2 in cap screw 9 from the auxil iary lamp kit With horn kit Select the 3 8 16 x 3 in silver finished screw from the horn kit With the auxiliary lamp support bracket 7 positioned with the wiring holes facing downward assemble the support bracket and accessories in combination to the upper shock mount sliding the selected screw through the combination For the combination of support bracket windshield and horn See Figure 2 For the combination of support bracket and horn See Figure 3 For the combination of support bracket and wind shield See Figure 4 Fasten with the flat washer and acorn nut removed from the shock absorber mount See the Service Parts illustration Apply Loctite 243 blue to the threads and install the original 5 16 24 x 1 2 in socket head screw removed from the right side of the rigid fork and a 5 16 in internal tooth lockwasher 12 from the kit onto the left side to fasten the auxiliary lamp bracket long tab to the rigid fork Obtain the 5 16 24 x 7 8 in socket head screw 11 and another 5 16 in internal tooth lockwasher 12 from the kit Apply Loctite 243 blue to the threads and fasten the screw and lockwasher through the brake line P clamp and through the right side long auxiliary lamp support bracket long tab to the rigid fork Apply Loctite 243 blue to the threads and tighten the upper shock mounting bolts to 45 50 ft lbs 61 0 67 8 Nm
5. from tool tip area and heat shrink attachment Avoid directing the heat toward any fuel system com ponent Extreme heat can cause fuel ignition explo sion resulting in death or serious injury Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed Be sure to turn the ON OFF switch to the OFF position after use Use the Ultra Torch UT 100 Kent Moore Part No HD 39969 or other radiant heater to heat from the center of the crimp out each end until the sealant comes out both ends Connect the Auxiliary Lamps to Power 1 Connect the white power lead to a power source For 2003 and earlier models a Cut the connector from the white power lead on the lamp wire harness b See Service Parts illustration Crimp the ring terminal on the lead c See Figure 11 Remove the nut on the copper stud BAT terminal of the main circuit breaker d Add the ring terminal on the white power lead and install the nut For 2004 and later models a See Figure 12 Route the white wire and connector to the B connector 160B b Mate the connector halves Use the cable ties to secure any excess wire to the bike to prevent damage or interference with operation J03497 i06422 Tn Figure 11 2 into 1 Splice i06825 Figure 11 Electrical Panel and Main Circ
6. ol clamp J03497 i06821 Ground BK Lamp switch Un terminated W Fuse holder w 15 Amp fuse Lamp circuit Wire wire with B connector Figure 7 Auxiliary Lamp Wire Harness i02280 Figure 8 Lamp Switch Mounting 4of8 Connect the Lamp Switch Circuit 1 See Figure 9 Route the unterminated black wire 2 from the harness to the 2 lamp wires and slide heat shrink tubing over the black wire 2 Follow the 2 into 1 Splice instructions on the next page to splice the black wire from the wire harness to the 2 lamp gray and black wires 3 Slide the conduit over the splice Splice in the Low Beam NOTE The auxiliary lamps can only be operated while the main head lamp is on low beam This function meets the requirements of many state and local laws CAUTION When routing wire through frame and front fork make sure wire is clear of moving parts heat sources and pinch points to avoid a possible short circuit 1 Remove the headlamp trim ring and headlamp 2 Separate the connector from the bulb 3 See Figure 10 Route the unterminated white wire from the auxiliary lamp harness through the grommet in the head light housing NOTE To route the wire through the grommet push a hooked piece of wire through the grommet fromthe inside of the headlamp hous ing Soap the white wire and pull it back through the grommet with the hooked wire 4 Cut the yellow low beam lead 1 5 in 38 1 mm from the headlamp c
7. onnector to leave sufficient length for a splice 5 Follow the 2 into 1 Splice instructions on the next page to splice the cut end of the yellow wire from the connector to the white and yellow wires from the headlamp housing grommet NOTE If the white wire from the harness does not fit through the grom met the white wire may be spliced to the yellow wire outside the headlamp housing 6 Connect the connector to the spade connectors on the headlamp and install the headlamp and trim ring in the headlamp housing J03497 i02295 eps 1 Heat shrink tubing 2 Black wire from kit harness 3 Splice connector 4 Lamp wires 5 Conduit Figure 9 Connect the Lamp Wires to the Kit Harness i02294b 1 Unterminated white wire from auxiliary lamp 2 Yellow low beam wire Figure 10 Splice the Unterminated Wire to the Headlight Yellow low beam Lead 5 of 8 2 into 1 Splice 1 2 Strip 3 8 in 9 5 mm of insulation off the wire ends See Figure 11 Use the blue 14 16 gauge crimp cavity of the crimping tool kent Moore Part No HD 38125 8 to crimp one wire end in one end of the blue connector and 2 wire ends in the other end of the connector 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 Always keep hands away
8. ply line 2 Follow Service Manual instructions to remove the seat WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 Disconnect the negative battery cable from the battery WARNING Stop the engine when refueling or servicing the fuel system 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 4 Follow the Service Manual instructions to remove the fuel tank Remove the Existing Hardware 1 See Figure 1 Remove the socket head screw 4 and the brake line P clamp 8 from the right side of the rigid fork Save the P clamp 2 Remove the socket head screw 7 and external tooth lockwasher 5 from the left side Save the screw 3 Remove the original acorn nut 1 a flat washer 2 and bolt 3 holding the upper shock absorber Save the wash ers and the acorn nut Acorn nut Washer 2 3 8 Bolt Screw 1 2 in long Lockwasher Shock absorber Screw 3 8 in long Brake line P clamp 1 2 3 4 5 6 7 8 Figure 1 Mounting Hardware 1of8 Mount the Bracket 1 Identify the correct length 3 8 16 UNC screw for the com bination of accessories and add a flat washer from the shock absorber bolt Without horn kit See the Service Parts illustration Select th
9. tration Locate the outer trim ring 18 inner nesting ring 21 screw 19 and nut 20 Place the inner nesting ring on the lamp bulb purchased separately See Figure 6 Connect the black wire to the bulb spade terminal 2 next to the bulb indexing tab 1 on the bulb Install the gray wire on the remaining spade terminal Install the trim ring with the bulb in the housing with the screw and nut Use fish tape or wire to draw the lamp wire leads through the holes in the support bracket along the inside of the bracket and through the single exit hole inside the left side long mounting tab See the Service Parts illustration Slide conduit 17 over each wire until the end of the conduit is 2 inches inside the exit hole of the support bracket Trim the opposite end of the conduit to expose a short length of lamp wire Secure the wires to the inside of the right side long mount ing tab on the support bracket with 2 short cable straps 14 Install button plugs 8 in both ends of the support bracket J03497 2 3 ON o gt i06838 U clamp Support bracket Bevel washer Belleville washer Gray black wire GR BK Housing stud Washer Chrome acorn nut Figure 5 Auxiliary Lamp Bulb Terminals i06820 Bulb index tab Spade terminal Nesting ring index tab 2002 and later Figure 6 Auxiliary Lamp Bulb Terminals 3 of 8 Route the Wiring Harness 1 See Figure 7 Place the relay 1 of the
10. uit Breaker 2003 FXST shown Figure 12 B Connector 160B 2004 FXST shown 6 of 8 Ground the Auxiliary Lamps 1 See Figure 13 Route the ring terminated wire BK to the ground stud or any good electrical ground point 2 Remove the nut and add the ring terminal to the ground stud Tighten the bolt Return the Motorcycle to Service 1 Connect the negative battery cable to the battery 2 Turn the IGNITION switch to ON and test the auxiliary lamp switch and the lamps for operation 3 Aim the lamps forward then tighten the lamp mounting nuts securely Awarnina After installing seat pull upward on front of seat to be sure Figure 13 Ground Wire Location it is in locked position While riding a loose seat can shift 1999 FXST shown causing loss of control which could result in death or seri ous injury 00070a 4 Follow Service Manual instructions to install the seat Awarnine Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a J03497 7 of 8 SMOTORZ e Service Parts Part No 69286 05A Springer Auxiliary Lamp Kit i06815 Item Description Qty 1 Auxiliary lamp housing 2 Wire harness 3 Belleville washer 2 4 U clamp 2 5 Bevel washer 4 6 Flat washer 2 7 Bracket passing lamp support 8 Plug button 2 9 Cap screw hex socket 3 8 16 x 2 1 2
11. wire harness in the opening of the seat pan CAUTION When routing wires through the frame and front fork make sure the wires are clear of moving parts heat source and pinch points to avoid a possible short cir cuit 2 Route the black ring terminated wire 2 to a ground stud 3 Find the B connector 160B on the main wiring harness and route the white wire with connector 7 to the B con nector 4 Route the long center conduit along the frame backbone 5 Turn the lamp switch 3 and the lamp circuit conduit 6 to the left side of the motorcycle 6 Route the unterminated white wire to the headlamp 7 Cable tie the long center harness to the main wiring har ness Install the Lamp Switch 1 See Figure 8 Remove the lower screw and washer from the left handlebar switch housing clamp 2 See Service Parts illustration Mount the switch bracket 25 to the switch housing and tighten to 60 80 in Ibs 7 9 Nm 3 Route the switch wires along the underside of the left han dlebar push the switch 28 through the bracket opening and thread on the rubber switch boot 24 NOTE See the Service Parts illustration If the boot 25 becomes worn or damaged or is lost replace the boot to prevent mois ture from entering the switch 4 Replace the wire clips 16 in the handlebar capturing the auxiliary lamp switch wire 5 For International HDI models Place the fog lamp HDI switch label 27 on the clutch contr
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