INSTRUCTIONS - Harley
Contents
1. INSTRUCTIONS J01515 REV 3 31 99 Kit Number 91531 00 ACCESSORY FAN KIT HARLEY DAVIDSON General Remove And Relocate Stock Horn FLHT This kit fits 1992 and later FLHR and FLHT models 1 Refer to applicable Service Manual Section 8 Remove horn and its bracket Disconnect wires from horn and KIT CONTENTS remove large nut that secures horn to horn bracket Set horn aside See Service Parts on pages 4 6 for kit contents 2 Refer to FLT Service Manual Section 2 and remove Installation outer fairing NOTE 3 See Figure 1 Locate connector 2 refer to FLT Service Manual Appendix A Deutsch Electrical Connectors Follow directions given and remove socket terminal from cavity 6 yellow black wire Cut socket terminal from wire and cover wire end with electrical tape 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 the area where the horn is mounted The horn must be removed and relocated 4 See Service Parts illustration Locate horn relocation harness 14 from kit and insert socket terminal on yellow black wire into cavity 6 of connector 2B Plug two halves of connector together WARNIN 5 See Figure 1 Route black wire with double spade 1 Remove seat To avoid accidental start up of motorcycle and possible terminal on horn relocation harness to cigarette light2. Horn relocation harness not sold Nut 6 32 2 60031 61 Fan assembly not sold Washer rubber 1 4x3 4x3 64 6265 Nut flanged M6 7495 Mount rubber 3 not sold Nut 10 24 7624 Washer 1 4x5 8x1 16 6 6703 Nut 1 4 20 6 7686 OANODOARWNM In addition to the above Service Parts the following Fan assembly Part no 74454 00 Repair kits are available at your Harley Davidson dealer Fan motor Part no 74452 00 Thermostat Part no 74453 00 J01515 5 of 5
3. Figure 2 and use 10 24 nut 17 washers 10 and screw 4 to mount horn 9 Position horn so horn cover opening is facing downward 10 Cover terminals on stock horn leads with electrical tape and position leads so they will not be damaged Secure leads with a cable strap if necessary i01490 1 11 16 in gt 43 mm PEM nut or location for 7 32 in diameter hole Figure 2 Horn Mounting Hole Location FLHT Remove And Relocate Stock Horn FLHR 1 Refer to applicable Service Manual Section 8 Remove horn and its bracket Disconnect wires from horn and remove large nut that secures horn to horn bracket Remove horn from chrome cover Set horn aside 2 See Service Parts illustration Locate three horn brackets 12 and flat rubber washer 7 Slip rubber washer on horn stud Take three horn brackets and install large hole end on horn stud Secure with metric M6 nut 16 3 Remove left front fuel tank Torx screw Mount horn without chrome cover at left front of fuel tank with Torx screw 4 Route stock horn wires forward and reconnect to horn Fan Installation REMOVING STOCK UPPER ENGINE MOUNTING BRACKET 1 On carburated models refer to applicable Service Manual Section 4 and remove enrichener control from upper engine mounting bracket 2 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 3 Remov
4. ad 1 Blue Plug not used 2 3 Plug not used Blue black wire 4 Black connect to Black fan motor lead 4B connect to 4A P amp A Acc connector 15 amp fuse amp fuseholder Thermostat mount to air cleaner backplate with 6 32 screws and nuts Ring terminal to silver stud main circuit 94O breaker L7 Horn terminals 7 x Horn relocation harness for FLHT models item 14 in list ra on page 5 Horn bracket item 12 in list on page 5 Yellow black m connect to cavity 6 of connector 2B Black wire connect to Black lead at i kN cigarette lighter J01515 4of5 Part No 91531 00 MOTOR SMATORZ Service Parts Accessory Fan Kit Hole with grommet through which fan motor leads are routed Fan cover screw r Cable strap loca i tion to secure fan motor leads Stock hardware Fan cover assembly is assembled on fan motor as received in kit Exploded view has been used for illustration purposes only Stock hardware inner primary cover Item Description Qty Part No Description Part No Cable strap 3 10065 Washer 10 6716 Fan mount top engine mount not sold Bracket enrichener control not sold Screw 6 32x3 8 in 2 2517 Horn bracket straight not sold Screw 10 24x1 2 in 2592 Fan harness not sold Bracket lower mounting not sold
5. e bolt attaching stabilizer link to upper engine mounting bracket Retain bolt nut and washer for reattaching stabilizer link later J01515 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 vacuum hoses Remove upper engine mounting bracket CONNECTING ACCESSORY FAN HARNESS 1 See Figure 3 and Service Parts illustration Connect ring terminal on accessory fan harness 13 to silver stud on main circuit breaker 2 Connect socket connector 4B on accessory fan harness to pin connector 4A P amp A accessory connector CAUTION Due to the different air cleaner backplate configurations take care to mount the thermostat in a suitable location in the next 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 Refer to applicable Service Manual Section 4 and remove air cleaner backplate Position the thermostat part of accessory fan harness on backplate to rear of carburetor as described in CAUTION above Mark thermostat mounting hole locations on backplate Drill two 5 32 in holes in backplate and mount thermostat with 6 32x3 8 in screws 3 and nuts 6 4 Mount fan relay in a vertical position mounting hole up and sec
6. er personal injury disconnect the battery cables negative Disconnect black wire from cigarette lighter Connect cable first before performing any of the following pro double spade terminal to cigarette lighter and reconnect cedures If the positive cable should contact ground stock black wire on the open double spade terminal with the negative cable installed the resulting sparks may cause a battery explosion and could result in death or serious injury 6 Connect the two remaining terminals on the horn relocation harness to the horn terminals The horn is not polarity sensitive so leads may be attached to either 2 Disconnect battery negative cable first horn terminal 7 See Service Parts illustration Locate two horn brackets 12 and flat rubber washer 7 Slip rubber washer on horn stud Take two horn brackets and install large hole end on horn stud Secure with metric M6 nut 16 f1317c8x Connector 2 x grey 5 2 O 6 i o o o ae 0 o o N 2 5 A NN i e ara YV Horn bracket racket N mounting point g 2 a gt X Cigarette lighter Figure 1 Outer Fairing Removed FLHT Models 1of5 8 See Figure 1 Mount horn to right support bracket with 10 24x1 2 screw 4 and washer 10 Thread screw into PEM nut If right support bracket does not have PEM nut drill a 7 32 in hole at the location shown in
7. essory fan harness under seat so harness and fuseholder will not be pinched damaged when seat is installed Secure harness with cable straps from kit 17 Carefully remove blocking from under rear of fuel tank and install screw at rear of fuel tank Awarnine Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in personal injury and could result in death or serious injury 14 Reconnect battery positive cable first 15 Install seat WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift position during vehicle operation and startle the rider and could result in death or serious injury NOTE The cooling fan is thermostatically controlled and will only operate when the thermostat senses cooling air temperature of approximately 140 F Cooling air movement is from left to right that is air is drawn in through slots in fan cover and blown across cylinders and cylinder heads 3 of 5 SMOTOR e Part No 91531 00 Service Parts Accessory Fan Kit Fan relay amp im connector Cavity Wire color 30 Black 85 Black 86 Blue 87 Blue black 87A Not used Fan harness item 13 in list on page 5 Black wire con nect to Blue fan Cavity Wire color motor le
8. nuts 18 on upper studs Tighten finger tight 9 See Service Parts illustration Install lower mounting bracket 5 1 4 in ID flat washer and 1 4 20 locknut on rubber mount stud Tighten finger tight 10 Remove upper front bolt and washer from inner primary housing Insert bolt through lower mounting hole in lower mounting bracket and tighten to 18 21 ft lbs 24 28 Nm 11 Tighten the three 1 4 20 fan mounting nuts to 72 96 in Ibs 8 11 Nm 12 Route fan motor leads over upper engine mounting bracket at location indicated with a dotted line in Service Parts illustration Install a cable strap to secure fan motor leads as shown CAUTION 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 Connect motor leads to the sealed butt connectors on the accessory fan harness 13 Connect as follows Blue fan motor lead to Black harness lead Black fan motor lead to Blue Black harness lead 14 Refer to FLT Service Manual Appendix A SEALED BUTT SPLICE CONNECTORS for instructions on crimping and heating connectors to melt the sealant J01515 RA SS Va Mn CS 4S a Figure 3 View With Seat Removed 15 On carburated models mount enrichener control to enrichener bracket 16 See Service Parts illustration Check that a cable strap secures fan motor leads at fan mount 2 Arrange acc
9. ure with an existing stock mounting screw or secure with a cable strap from kit MOUNTING FAN ASSEMBLY 1 See Service Parts illustration Install fan mount 2 upper engine mounting bracket from kit on front and rear cylinder heads and secure with stock bolts and washers Tighten bolts to 28 35 ft lbs 38 47 5 Nm 2 Install upper stabilizer link on upper engine mounting bracket with stock bolt and washer On carburated models mount enrichener bracket to underside of upper engine mounting bracket Check that fuel vacuum hoses are routed properly 3 Secure stabilizer link and if applicable enrichener bracket with stock bolt nut and washer Tighten bolt to 18 22 ft lbs 24 30 Nm 4 Insert rubber mount stud 8 through mounting hole in fan mount 2 and secure with 1 4 in ID washer 9 and 1 4 20 nut 18 Tighten nut to 72 96 in lbs 8 11 Nm 5 Repeat Step 4 for other mounting hole in fan mount 2 6 See Service Parts illustration Insert rubber mount stud 8 through bottom mounting hole in fan cover assembly and secure with 1 4 in ID washer 9 and 1 4 20 nut 18 Tighten nut to 72 96 in Ibs 8 11 Nm 7 Position fan assembly so holes in upper mounting tabs on fan cover assembly engage rubber mount studs in upper engine mounting bracket 2of5 1431b8x i Main circuit Silver post breaker P amp A Accessory connector 4A 8 Install 1 4 in inside diameter ID flat washers 9 and 1 4 20 lock
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