passing lamp/directional signal relocation kit - Harley
Contents
1. Connector 8 70581 73 2 Spacer 2 5774 8 Shrink tube 8 67113 83 3 Lockwasher 2 7127 9 Connector 6 place 73156 96BK1 4 Nut acorn 2 7736 10 Mounting brackets 2 68519 68A 5 Nut locking 2 7778 11 Housing assembly directional 69084 04 signal front 2 Kit 69079 04 6 Cable strap 6 10181 12 Housing assembly directional 69085 04 signal front 2 Kit 69080 04 J02912 6 of 62. 1 Directional signal connector 2 Right directional signal wires is02635 S 1 Acorn nut 2 Spacer 3 Passing lamp 3 Left directional signal wires Figure 2 Disconnect Dorectional Signal Wire from the 6 Place Connector J02912 Figure 4 Remove the Passing Lamp Acorn Nut 11 See Figure 5 Route the passing lamp wire 1 through the spacer 2 saved in Step 10 and the hole at the top of the mounting bracket 3 Position the mounting bracket against the passing lamp bracket 4 Position the notch 2of6 in the mounting bracket toward the rear Secure the mounting bracket using a lock nut 5 supplied in the kit is02636 Passing lamp wire Spacer Mounting bracket Passing lamp bracket Lock nut meo NA Figure 5 Install the Mounting Bracket NOTE See Figure 6 Make sure the passing lamp and directional signal wires 1 and 2 are routed through the notch at the rear of the mounting bracket and are not pinched when the direc tional signal is installed 12 Install the directional signal housing 3 using two screws 4 supplied in the kit 13 Install the bulb 5 and lens 6 Saved during removal 14 Repeat Steps 10 through 13 for the left side 15 Route the directional signal wires to the connector Secure the wires to the existing harnesses using cable straps J02912 is02637 9 Passing lamp wire Directional signal wires Directional s
3. asher Spacer Mirror Internal tooth lockwasher Acorn nut Spacer PaO Peonn 9 See Figure 3 Trace the right passing lamp wire 1 back to the connector 2 and cut the wire approximately 2 3 inches 50 75 mm 3 from the connector Repeat for the left passing lamp wire 4 is02634 Right passing lamp wire Connector 2 3 inches 50 75 mm Pon gt Left passing lamp wire Figure 1 Install Mirror Hardware 7 Remove and retain the lenses and bulbs from both direc tion signal housings 8 See Figure 2 Disconnect or cut the directional signal wires Connector Method Locate the directional signal 6 place connector 1 located under the fuel tank and disconnect the connector from the main vehicle harness Record the location of the directional signal wires in the connector Remove the directional wires 2 and 3 from the connector Wire Splicing Method Trace the directional signal wires back to where they exit from under the fuel tank Label the wires according to which directional signal they are routed to Cut the wires leaving approximately 2 3 inches 50 75 mm of wire extending from the point where the wires exit under the tank Figure 3 Cut the Passing Lamp Wires NOTE Hold the passing lamp in place when the acorn nut is removed 10 See Figure 4 Remove the acorn nut 1 and spacer 2 from the passing lamp 3 Retain the spacer and discard the acorn nut is02633
4. cMOTOR HARLEY DAVIDSON WY J02912 INSTRUCTIONS REV 2006 04 09 PASSING LAMP DIRECTIONAL SIGNAL RELOCATION KIT GENERAL Kit Number 69079 04 69080 04 Models These kits fit 2002 and later FLSTF and 2006 and later FLST models Kit 69079 04 is for North American models Kit 69080 04 is for International models Additional Parts Required Auxiliary lamp kit part number 69287 05 must be installed prior to 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 model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 10 and Table 1 INSTALLATION 1 Remove the seat according to the procedure in the appli cable Service Manual IWIN NIN To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a AWARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the r
5. esulting sparks can cause a battery explosion which could result in death or serious injury 00049a 2 Disconnect battery cables negative cable first J02912 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 NOTE There are two possible methods of connecting the directional signal wires using the 6 place connector or by splicing the wires using connectors supplied in the kit If the splicing method is selected it will not be necessary to remove the fuel tank However the splices will be visible Proceed to Step 4 3 Remove the fuel tank according to the procedure in the appropriate Service Manual 4 See Figure 1 Remove the existing right directional signal according to the procedure in the appropriate Service Manual Save the internal tooth lockwasher 1 and spacer 2 5 Place the internal tooth lockwasher 1 and spacer 2 saved in Step 4 on the mirror shaft and install the mirror 3 in the mounting bracket Secure the mirror using an internal tooth lockwasher 4 and acorn nut 5 both sup plied in the kit If the acorn nut 5 bottoms without tightening add a spacer 6 from the kit in the location shown 6 Repeat Steps 4 and 5 for the left directional signal 1 of 6 is02632 Internal tooth lockw
6. g lamp wire Completed splice OSE Oo Ne Figure 7 Connect the Passing lamp Wiring NOTE Depending on the electrical connection method 6 place con nector or wire splicing that was chosen in Step 8 of Installation use the appropriate connection procedure that follows for your application Connect Directional Signal Wiring Using 6 Place Connector NOTE If needed a new 6 place connector is included in the kit 1 See Figure 8 Install the directional signal wires 1 and 2 in the same connector positions as noted during removal After all the wires have been seated in the connector swing the latch 3 down to lock the wires in place 2 Connect the 6 place connector to the vehicle harness J02912 is02639 1 Right directional signal wires 2 Left directional signal wires 3 Latch Figure 8 Install Directional Signal Wires in 6 Place Connector 3 Proceed to Final Assembly Connect Directional Signal Wiring Using Splice Connectors 1 See Figure 9 Cut the terminal 1 from each of the direc tional signal wires 2 Strip approximately 3 8 inch 10 mm of insulation from each end of the directional signal wires 3 Working on one pair of wires at a time slide a section of shrink tube 2 over one end of the wires Connect the directional signal wire to its matching wire extending from the connector as noted during removal using a crimp connector 3 Crimp the connector using a Cr
7. ignal housing Screw 2 Bulb Lens DM eo NS Figure 6 Install the Directional Signal Connect Passing Lamp Wiring 1 See Figure 7 Strip approximately 3 8 inch 10 mm of insulation from each end of the passing lamp wires 1 and 2 Slide a section of shrink tube 3 over one of the wires and connect the passing lamp wires using a crimp con nector 4 Crimp the connector using a Crimp Tool HD 38125 8 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 Avoid directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury Avoid directing heat toward any electrical system compo nent other than the connectors on which heat shrink work is being performed Always keep hands away from tool tip area and heat shrink attachment 3of6 3 Slide the shrink tube 3 over the connector 4 and using UltraTorch UT 100 HD 39969 Robinair Heat Gun HD 25070 with heat shrink Attachment HD 41183 or other suitable radiant heating device heat the shrink tube to encapsulate the crimp connector Let the splice 6 cool is02638 Passing lamp wire to right passing lamp Passing lamp wire to connector Shrink tube Crimp connector Left passin
8. imp Tool HD 38125 8 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 4 Slide the shrink tube 2 over the crimp connector 3 and using UltraTorch UT 100 HD 39969 Robinair Heat Gun HD 25070 with heat shrink Attachment HD 41183 or other suitable radiant heating device heat the shrink tube to encapsulate the crimp connector Let the splice 4 cool 5 Repeat Steps 1 through 4 for each pair of wires 6 Use cable straps to secure the wiring harness to the frame 4of6 FINAL ASSEMBLY IW N IN 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 NOTE Be sure that wiring harness does not get pinched between fuel tank and frame during tank installation 1 Install the fuel tank according to the pr
9. ocedure in the applicable Service Manual Os D Terminal Shrink tube Crimp connector Completed splice Directional signal harness Wires to harness connector PO Pena Figure 9 Splice Directional Signal Wires J02912 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 2 Connect the battery cables positive cable first 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 3 Install the seat according to the procedure in the applicable Service Manual 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 4 Turn ignition on and test the directional signals and passing lamps Tighten the directional signal and passing lamp hardware 5 of 6 SERVICE PARTS is02641 PP P i Jad Ka O Figure 10 Service Parts Passing Directional Signal Relocation Kit Table 1 Service Parts Table Item Description Quantity Part Number Item Description Quantity Part Number 1 Screw 4 2647B 7
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