Rear Turn Signal Relocation Kit Instruction Sheet - Harley
Contents
1. OE license plate bracket can be discarded e OE license plate mounting bracket IIO n m olol wD gt e OE license plate clamp Fasteners vary per model J03107 7 of72. left as appropriate The right turn signal has black BK and brown BN wires The left turn signal has black BK and violet V wires 6 Repeat for the opposite turn signal at the other end of the bar With Type I Turn Signal 1 See Figure 7 Obtain the directional bar 1 and two jam nuts 5 from the kit Screw a jam nut all the way onto each end of the directional bar with the counterbored side of the nut against the bar 2 Obtain the two vinyl covered electrical cables H D Part Number 32692 70 purchased separately Push one cable through each end of the directional bar to exit the bar at the nearest slot 3 Place a piece of shrink tube H D Part Number 67113 83 purchased separately onto the turn signal lead Splice the wire lead from the turn signal to the lead from the threaded end of the directional bar with a connector H D Part Number 70581 73 also purchased separately Position the shrink tube over the connector and heat with a flame or heat gun to seal the connection 4 Thread the turn signal lamp all the way onto the directional bar but do not tighten Mark the new end of the turn signal wire lead right or left as appropriate Repeat for the opposite side 3 of 7 Encase the wire from the right side turn signal lamp in small diameter conduit H D Part Number 70530 89 pur chased separately so the conduit begins inside the directional bar just past the slot Route the wire to the left side to join
3. of the fender surface with isopropyl alcohol Peel the liner from the adhesive backed clips 9 and position the clips so as not to make contact with the tire when riding Press the wire clips to the fender NOTE Make sure the turn signal wiring leads are not loose or bunched and are secured to the harness clips on the underside of the fender 2 Models with rear lighting circuit board Route the turn signal socket housings through the openings in the fender and tail lamp base and plug the left housing 18 and the right housing 19 into the correct receptacle of the rear lighting circuit board 3 ALL models Secure the wires to the wire clips making sure that the wires are taut and will not drag on the tire 5 of 7 RETURN TO SERVICE 1 Verify that the ignition key switch is turned to the OFF position Models with main fuse Refer to the service manual and follow the instructions given to install the main fuse Models with main circuit breaker Apply a light coat of Harley Davidson electrical contact lubricant H D Part Number 99861 02 petroleum jelly or corrosion retardant material to the negative battery terminal Refer to the ser vice manual and follow the instructions given to attach the negative battery cable Turn the ignition key switch to IGNITION IGN but do not start the motorcycle Test the turn signals for proper operation 3 Install the tail lamp lens to the tail lamp base with the two screws remo
4. the new pad 1 from the kit onto the fender aligning the holes with the three holes in the fender Make sure the pad will cover a 3 8 inch 10 mm diameter hole in the marked location d Mark the hole position with a center punch Place a wooden block between the rear tire and the underside of the fender Drill a 1 8 inch 3 mm pilot hole through the tape and fender followed by a 3 8 inch 10 mm diameter hole e Remove the wooden block and the tape Clean the fender of tape and drilling residue f Place the pad 1 onto the fender aligning the holes with the three holes in the fender g Mark the location on the pad that aligns with the new hole in the fender For models with FOUR license bracket holes in the fender a Place the new pad 1 from the kit onto the fender aligning the holes with the three holes in the fender b Mark the location on the pad that aligns with the new hole in the fender J03107 ALL models Remove the pad from the fender and cut an X pattern 2 at the mark as shown See Figure 7 Obtain the new license plate bracket 2 from the kit Route the wires for both turn signals through the leftmost hole in the license plate bracket the X cut in the pad and the leftmost hole in the fender Place the pad 4 onto the fender aligning the holes and X cut with the four holes in the fender Place the original license plate support bracket G onto the pad and fasten to the fende
5. the service manual and follow the instructions given to remove the main fuse Models with main circuit breaker 1 of 7 INN NIN To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative black battery cable from the negative battery terminal Retain all seat mounting hardware NOTE For 2004 and later XL Sportster models the negative battery cable is most easily disconnected at the engine crankcase TURN SIGNAL REMOVAL AND DISASSEMBLY Remove the two screws and tail lamp lens from the tail lamp base Determine if this vehicle has a rear lighting circuit board If YES continue below If NO proceed to Models without Rear Lighting Circuit Board Models with Rear Lighting Circuit Board 1 See Figure 2 Depress the lock tabs 1 on the left 2 and right 3 two way turn signal socket housings 18B and 19B to disconnect them from the rear lighting circuit board is04178 1 Lock tab 2 2 Left turn signal connector 3 Right turn signal connector cuts as shown in Figure 3 so the conduit will fit over the sealed connectors after the wires are spliced back together is05837 Figure 3 Cut Wire Ends with Connector 4 See Figure 3 Cut the black BK and
6. ater Two socket head screws H D Part Number 861 a 1987 and earlier Two hex head screws H D Part Number 3945 J03107 is05907 1 Type earlier style 2 Type Il later bullet style Figure 1 Turn Signal Types Tools and Supplies Required A Packard Crimping Tool HD 38125 8 is required for the proper installation of this kit An UltraTorch UT 100 HD 39969 Robinair Heat Gun HD 25070 with Heatshrink Attachment HD 41 183 or other suit able radiant heating device is also required Loctite 243 Threadlocker and Sealant Blue H D Part Number 99642 97 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 NOTE This instruction sheet references service manual information A service manual for your year and model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Contents See Figure 7 and Table 1 PREPARATION Models with main fuse WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 Refer to
7. brown BN wires approximately 4 6 inches 10 15 cm from the right turn signal socket housing 18B staggered as shown Cut the black BK and violet V wires of the left turn signal socket housing 19B in the same manner Save the cut wire ends with the connectors 5 Remove the turn signal assemblies and supports per the instructions in the service manual 6 See Figure 4 Remove the lens 5 from one of the rear turn signal housings 1 is05838 Turn signal housing Grommet Reflector Bulb Lens Support 1 2 3 4 5 6 7 Fasteners vary per model Figure 2 Turn Signal Connections 2 Push the turn signal socket housings and wires through the openings on each side of the tail lamp base 3 Reach under the fender and locate the fender clips that hold the turn signal wires in place Carefully pull the wires out of the clips and pull the turn signal connectors and wires out from under the fender NOTE The wires must be cut to fit through the new turn signal bar Remove the black conduit to allow splicing and stagger the J03107 Figure 4 Rear Turn Signal Typical 7 Carefully pry the reflector 3 and grommet 2 from the housing 1 Gently pull the wires out from the unthreaded housing hole 8 Remove the support 6 and fasteners 9 Repeat for the opposite turn signal then proceed to License Plate Bracket Removal Models without Rear Lighting Circuit Board 1 Remove one
8. cMOTOR HARLEY DAVIDSON WU J03107 INSTRUCTIONS REV 2008 12 17 REAR TURN SIGNAL RELOCATION KIT GENERAL Kit Number 68732 02A 68733 02A Models This kit is needed to complete the installation of certain saddle bags on specific FXD Dyna and XL Sportster motorcycles For model fitment information and affected saddlebag part numbers see the P amp A retail catalog or the Parts and Acces sories section of www harley davidson com English only NOTE This kit may be installed without saddlebags but this will result in open holes in the fender support covers The following hole plugs are available from a Harley Davidson dealer e Part number 56239 93 for 0 375 inch 9 5 mm diameter holes on FXD models e Part number 68446 00 for 0 344 inch 8 7 diameter holes on XL models e Part number 53377 04 for 0 400 inch 10 2 diameter holes on XL models Additional Parts Required See Figure 1 Models with earlier style turn signals will require the following items available from a Harley Davidson dealer e Two hole plugs H D Part Number 58765 85 e Two electrical cables H D Part Number 32692 70 e Two acorn nuts H D Part Number 7787 e One piece of shrink tube H D Part Number 67113 83 One connector H D Part Number 70581 73 e One small diameter conduit H D Part Number 70530 89 One large diameter conduit H D Part Number 70552 70 One cable strap H D Part Number 10065 e 1988 and l
9. inal equipment OE license plate bracket components Remove the license plate bracket assembly from the fender See Figure 7 Retain the hardware E for installation of the new bracket 2 from this kit TURN SIGNAL BAR ASSEMBLY AND WIRING See Figure 1 for turn signal identification With Type II Bullet Style Turn Signal 1 See Figure 5 Install a chrome jam nut 5 onto each end of the turn signal bar 6 with the counterbored side of the nut against the bar 2 Route the turn signal wires as follows a Into the turn signal housing 1 and through the threaded hole 2 b Through the recess cover plate 3 c Through the new lockwasher 4 d Through the chrome jam nut and into the hole in the end of the turn signal bar e Out the hole 7 a short distance from the end of the bar J03107 is05839 Turn signal housing Threaded hole Recess cover plate Lockwasher Chrome jam nut Turn signal bar Hole BO Oh ONE Figure 5 Turn Signal Bar 3 Continue pulling the turn signal wires through the hole 7 while guiding the turn signal reflector Figure 4 item 3 and grommet 2 into the turn signal housing 4 Screw the turn signal housing 1 onto the threaded end of the turn signal bar being careful not to twist the wires Leave the turn signal housing loosely fastened to the bar 5 Install the bulb 4 and lens 5 If desired mark the new end of the turn signal wire lead right or
10. nal bar 8 ALL models Rotate the turn signals so that they are horizontal and pointed to the rear Tighten the chrome jam nuts so the turn signals will not loosen and rotate out of alignment during vehicle operation WIRE SPLICING Splicing of wire leads is necessary in the installation of the Rear Turn Signal Relocation Kit to the motorcycle Refer to the service manual for proper wire splicing procedures NOTES Remove excess length from the turn signal wires before splicing Stagger the sealed connectors so the conduit will fit over the wires Trim the conduit slightly longer to allow the excess to cover the splice connections Models WITH Rear Lighting Circuit Board 1 Crimp the brown BN wire from the right turn signal lamp A and the brown BN wire from the two way turn signal socket housing B cut off earlier into the ends of one of the sealed splice connectors 8 from the kit Crimp the black BK wires from the lamp and socket housing into the ends of another sealed splice connector 2 Crimp the violet V wire from the left turn signal lamp C and the violet V wire from the remaining two way turn signal socket housing D cut off earlier into the ends of a third sealed splice connector Crimp the black BK wires from the lamp and socket housing into the ends of the remaining sealed splice con nector Models WITHOUT Rear Lighting Circuit Board 1 Locate the original turn signal wiring on the moto
11. of the rear turn signal lamp assemblies See the service manual Cut the wire approximately two inches 2of7 50 mm from the turn signal Label the wire on the motorcycle wiring harness right or left as appropriate Repeat for the opposite turn signal lamp assembly Discard the original turn signal mounting nuts but save the turn signal lamps flat washers and lock washers 2 See Figure 7 Place one of the flat washers from the pre vious step on a new screw purchased separately Insert the screw through the attaching hole in the fender and the fender support Place one of the original lockwashers on the fastener threads and apply a few drops of Loctite 243 Blue to the threads Secure the fender support to the rear fender with a new acorn nut purchased separately Tighten the fas teners to 12 18 ft lbs 16 3 24 4 Nm Repeat for the opposite side 3 Remove the mounting stud from the turn signal lamp assembly and discard the stud 4 Remove the turn signal lens from the lamp assembly Remove the wire and grommet from their original position in the turn signal lamp body Insert a new hole plug purchased separately into the vacated hole in the turn signal lamp body from the inside so the small end of the plug is outside the lamp body Assemble the lamp 5 Repeat for the opposite turn signal then proceed to License Plate Bracket Removal LICENSE PLATE BRACKET REMOVAL Note the parts and orientation of the orig
12. r through the top hole only with original fasteners E removed earlier is05842 License plate bracket mounting pad X cut in pad Rear fender Leftmost support bracket mounting hole Wiring hole location Measure about 0 76 inch 19 4 mm to left Measure about 0 30 inch 7 6 mm down Original license plate support bracket Oo oo eS Ni Figure 6 License Plate Support Bracket and Pad NOTE The right turn signal has black BK and brown BN wires The left turn signal has black BK and violet V wires 5 Insert the threaded studs on the turn signal bar 1 through the two holes in the new license plate bracket 2 the original license plate support bracket G the pad 4 and the fender Fasten the studs to the fender with the original fasteners E removed earlier NOTE Ambient temperature should be at least 60 F 16 for proper adhesion of the reflector to the license plate bracket 6 Clean the license plate bracket surface with isopropyl alcohol and allow to dry thoroughly Peel the liner from the back of the new red reflector 3 and apply the reflector to the license plate bracket Press the reflector firmly to the bracket and hold for about one minute Models with rear lighting circuit board Slide a conduit 10 from the kit over each pair of turn signal wires Push 4 of 7 the conduit through the wire hole in the fender pad and bracket and back into the holes in the turn sig
13. rcycle wiring harness 2 Trim the turn signal wires to the necessary length to allow splicing to the original wires on the motorcycle 3 Slide a conduit 10 from the kit over each pair of turn signal wires Push the conduit through the wire hole in the fender pad and bracket and back into the holes in the turn signal bar J03107 4 Splice the wire from one turn signal lamp to the corre sponding wire on the motorcycle with a sealed splice connector 8 from the kit Repeat for the remaining turn signal wires ALL models 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 directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid directing heat toward any electrical system compo nent 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 5 Use a heat gun or suitable radiant heating device to apply heat from the center of the crimp out to each end until the sealant comes out of both ends WIRE ROUTING AND CONNECTION NOTE Ambient temperature should be at least 60 F 16 for proper adhesion of the clips to the fender 1 Clean the inside
14. the left directional lead and trim the conduit NOT the wire approximately 2 inches 50 mm past that point Use the cut off piece of small diameter conduit to encase the left side turn signal lead Begin the conduit inside the directional bar just past the slot Trim the conduit NOT the wire approximately 2 inches 50 mm past the point where it joins the right side turn signal lead Encase the wires from both turn signals in large diameter conduit H D Part Number 70552 70 purchased sepa rately so the larger conduit overlays the two ends of the smaller conduit by approximately 1 4 1 2 inch 6 13 mm Position a cable strap H D Part Number 10065 purchased separately at this point tightening it around the larger conduit to hold the wires and smaller conduit in place Remove the three 1 4 20 Phillips screws and hex nuts that attach the license plate support bracket to the fender Save one screw but discard the remaining fasteners Remove the entire license plate bracket assembly and set aside for later assembly TURN SIGNAL BAR AND LICENSE PLATE BRACKET INSTALLATION 1 See Figure 6 For models with THREE license bracket holes in the fender a Place apiece of masking tape on the rear fender 3 in the area to the left of the three license plate bracket mounting holes above the tail lamp b Measure from the left lower hole 4 per dimensions 6 and 7 and mark the location for hole 5 on the tape c Place
15. ved earlier 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 4 Refer to the service manual and follow instructions to install the seat SERVICE PARTS is05844 Figure 7 Service Parts Rear Turn Signal Relocation Kit J03107 6 of 7 SERVICE PARTS Table 1 Service Parts Table Kit Item Description Quantity Part Number Rear Turn Signal 1 Turn signal bar assembly 68967 04 Relocation Kit 68732 02A Domestic Rear Turn Signal 1 Turn signal bar assembly 68965 04 Relocation Kit 68733 02A HDI Items common 2 Bracket license plate 60013 02 to BOTH kits 3 Reflector red 59988 72A 4 Pad rear turn signal bar mounting 68456 89 5 Hex jam nut 5 16 18 2 7849 6 Lockwasher 5 16 2 7042 7 Cover turn signal recess chrome 2 68028 03 8 Connector sealed splice red 4 70585 93 9 Clip adhesive backed 2 10102 10 Wire conduit 2 Not sold separately Items mentioned in text but not included in kit Turn signal right rear brown and black wires Includes item B Two way socket housing with brown and black wires Turn signal left rear violet and black wires Includes item D Two way socket housing with violet and black wires Original equipment OE license plate bracket components
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