CHROME FAN KIT - Harley
Contents
1. cMOTOR HARLEY DAVIDSON WY J04347 INSTRUCTIONS REV 2011 05 16 CHROME FAN KIT GENERAL Kit Number 91196 08 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 AWARNING 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 7 and Table 1 NOTE A horn is required for compliance with most state s laws and for operation in many parts of the world INSTALLATION 1 Refer to Service Manual and remove seat IWAN IN To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect battery negative cable Horn Relocation NOTE This cooling fan is designed to provide supplemental cooling for motorcycles subjected to long periods of idling parade duty The fan is mounted on the left side of the engine in th2. d connector 8 Lead yellow black to cavity 6 connector 3 Lead to fan motor lead 9 Lead to cigarette lighter lead 4 Lead to fan motor lead 10 Power lead ring terminal 5 Thermostat 11 Accessory connector 6 FLHT horn relocation harness 12 Fuse holder 15 amp Figure 6 Wire Harness 3 Insert rubber mount stud 9 through mounting hole in fan in ID washer 10 and 1 4 20 nut 18 Tighten nut to 72 96 mount 2 or 3 and secure with 1 4 in ID washer 10 and 1 4 20 nut 18 Tighten nut to 72 96 in lbs 8 11 Nm NOTE When tightening the locknuts on the rubber mounts do not allow the rubber mounts to twist Twisted mounts may cause equipment damage 4 See Figure 7 Insert rubber mount stud 9 through bottom mounting hole in fan cover assembly and secure with 1 4 J04347 in Ibs 8 11 Nm Position fan assembly so holes in upper mounting tabs on fan cover assembly engage rubber mount studs in upper engine mounting bracket Install 1 4 inch inside diameter ID flat washers 10 and 1 4 20 locknuts 18 on upper studs Tighten finger tight 3 of 5 7 See Figure 5 Remove front engine case bolt from engine Install stud into engine case Tighten stud to 15 19 ft lbs 20 3 25 8 Nm 8 See Figure 7 Install lower mounting bracket 5 1 4 inch ID flat washer and 1 4 20 locknut on rubber mount stud Tighten finger tight 9 Insert fan lower mounting bracket onto engine stud Install nut and tighten finger tight Po
3. e area where the horn is mounted The stock horn must be removed Remove Stock Horn 1 Follow Service Manual instructions to remove stock horn and its bracket 2 Assemble new horn 69043 96B to bracket 69135 04 using screws 3658 and washers 7069 J04347 3 Remove right front fuel tank TORX screw 4 Mount horn at front of fuel tank with TORX screw Verify there is adequate room between horn bracket and fuel tank to prevent paint damage Tighten screw to 15 20 ft Ibs 20 27 Nm is05140a 1 Horn mounting location Figure 1 Horn Relocation Remove Stock Upper Engine Mounting Bracket 1 Remove screw securing rear of fuel tank and gently raise fuel tank to gain access to upper engine mounting bracket Place suitable blocking under tank 2 On 2007 models remove bolt attaching stabilizer link to upper engine mounting bracket 3 Remove two bolts and washers securing upper engine mounting bracket to front and rear cylinder heads Retain bolts and washers for attaching new upper engine mounting bracket from kit 4 Note position of fuel hose Remove upper engine mounting bracket 5 Connect horn relocation harness to horn 6 Route stock horn wires forward towards relocated horn 7 See Figure 7 Cut ends off stock horn wires and strip wires 3 8 inch Follow instructions in Service Manual SEALED 1of5 BUTT SPLICE CONNECTORS to crimp and heat con nector 17 to be spliced 8 Route horn ha
4. gative battery cable 3 Install the seat 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 Operation The cooling fan is thermostatically controlled and will only operate when the thermostat senses cooling air temperature of approximately 140 F 60 C Cooling air movement is from left to right Air is drawn in through slots in the fan cover and blown across the cylinders and cylinder heads SERVICE PARTS is05136 to Figure 7 Service Parts Fan Kit for Touring Models J04347 4of5 Table 1 Service Parts Table Item Description Quantity Part Number Cable strap 3 10065 2 Fan mount top engine mount 2007 bracket 16317 00 3 Fan mount top engine mount 2008 and later bracket 16313 08 4 Screw 6 32 x 3 8 inch 2 not shown Not Sold Separately 5 Bracket lower mounting 91197 08 6 Stud fan mount 3097 7 Nut 6 32 nylon insert 2 not shown 60031 61 8 Horn assembly 69000014 9 Mount rubber 3 62901 00A 10 Washer 1 4 x 5 8 x 1 16 6 6703 11 Bracket horn 69135 04 12 Screw horn 3 3658 13 Washer horn 3 7069 14 Harness fan Not Sold Separately 15 Fa
5. n and cover assembly See repair kits below 16 Harness horn relocation Not Sold Separately 17 Butt splice connector 2 not shown 70585 93 18 Nut hex 1 4 20 nylon insert 6 7686 19 Medallion fan cover chrome not shown 99598 00 20 Nut 3 16 18 7766 21 Wire harness adapter 70310 04 22 Butt splice connector not shown 70586 93 23 Cable strap 4 not shown 10039 Repair kits available A Fan motor 74452 00A B Thermostat 74453 00 C Fan assembly chrome 74456 00B J04347 5 of 5
6. rness relocation to stock horn wires and cut to proper length Connect wires with sealed butt splice connector 17 is04516 1 Ground stud 2 Accessory connector is04517 1 Backplate 2 Thermostat Figure 4 Thermostat Mounting 3 Battery positive connector Figure 2 2007 and Later Under Seat Connectors 1 Battery ground stud 2 Accessory connector 3 Battery positive connector 1 Front engine case bolt Figure 3 2008 and Later Under Seat Connectors J04347 Figure 5 Mounting Point Connect Accessory Fan Harness 1 Connect fan harness power lead to power source See Figure 2 and Figure 3 for the battery positive con nector on your model year a Locate the battery positive connector under the seat b See Figure 7 Mate the kit wire harness adapter 21 to the battery positive connector c Cut the ring terminal off the lead fuseholder lead of the fan harness and cut the length of the battery positive adapter lead to reach the end of the fuse holder lead on the fan harness d Strip 3 8 inch wire from the ends of the leads and follow Service Manual instructions in SEALED BUTT SPLICE CONNECTORS to crimp and heat connector 22 to splice lead of the battery positive adapter to the fuse holder lead on the wire harness 2 Connect socket connector on accessory fan harness Figure 6 to pin connector 11 on accessory connector 2 Fig
7. sition lower mounting bracket so rubber mounts are not stressed and tighten nut for lower bracket to 15 ft lbs 20 3 Nm 10 Tighten the three 1 4 20 fan mounting nuts to 72 96 in Ibs 8 11 Nm 11 See Figure 7 Peel off medallion 19 backing align logo and affix to hole in cover Tape is strong and will not allow repositioning 12 Route fan motor leads over upper engine mounting bracket 2 or 8 Install a cable strap to secure fan motor leads NOTE Make certain motor leads are connected as specified in the next step Reversed leads would reverse fan rotation and decrease cooling efficiency which could cause engine damage 13 See Figure 6 Connect motor leads to the sealed butt connectors on the accessory fan harness Connect as follows Black fan motor lead to Black harness lead Blue fan motor lead to Blue Black harness lead 14 Follow Service Manual instructions in SEALED BUTT SPLICE CONNECTORS to crimp and heat connectors to melt the sealant 15 See Figure 7 Cable strap 1 fan motor leads to fan mount top engine mount 2 or 3 between the center and left side mounting hardware 16 Arrange accessory fan harness under seat so harness and fuseholder will not be pinched damaged when seat is installed 17 Secure harness with cable straps 23 from kit Return Motorcycle to Service 1 Carefully remove blocking from under rear of fuel tank and install screw at rear of fuel tank 2 Reconnect the ne
8. ure 2 and Figure 3 NOTE Due to the different air cleaner backplate configurations take care to mount the thermostat in a suitable location in the next 2of5 step Make certain thermostat will not contact cylinder head or prevent normal mounting of backplate Orient thermostat so its leads are routed away from components that could damage them 3 See Figure 4 Follow Service Manual instructions to remove air cleaner backplate Mount fan relay in a vertical position mounting hole up to a stable position on the frame that allows adequate seat clearance Depending on model year application secure in an open relay socket with an existing stock mounting screw or secure with a cable strap from kit Mount Fan Assembly 4 Position the thermostat part of accessory fan harness 1 See Figure 7 Install fan mount 2 or 3 top engine on backplate to rear of intake and described in NOTE mount kit 1631 7 00 for 2007 models and kit 16313 08 for above Mark thermostat mounting hole locations on 2008 models on front and rear cylinder heads and secure backplate with stock bolts and washers Tighten bolts to 28 35 ft lbs 5 Drill two 5 32 inch holes in backplate eae 2 2007 Models Secure stabilizer link with stock bolt nut 6 See Figure 7 Mount thermostat with 6 32x3 8 inch screws and washer Tighten bolt to 18 22 ft lbs 24 30 Nm 4 and nuts 7 is04519 1 Fan harness 7 Horn terminal 2 Fan relay an
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