Chrome Horn Kit Instruction Sheet - Harley
Contents
1. 14 15 16 Install the enrichener cable to the new bracket Tighten the enrichener cable nut 4 securely Install the rubber horn mount 5 onto the enrichener bracket 1 with the 5 16 18 flanged locknut from the kit Tighten the nut to 60 180 in Ibs 6 7 20 3 Nm Obtain the horn and chrome cover assembled earlier Install the ground wire from the kit to the ground terminal on the horn Route the ring terminal end of the ground wire to the rear cylinder head top motor mount screw 6 Remove the screw and slip the ring terminal onto the screw threads Install the screw and tighten to 25 30 ft Ibs 34 41 Nm Position the horn assembly 7 onto the rubber mount 5 stud Install the lock washer 8 over the stud Secure the assembly with the acorn nut 9 from the kit Tighten to 60 180 in Ibs 6 7 20 3 Nm Connect the horn wire terminal clips from the main wire harness to the spade connections on the new horn Pro ceed to Final Assembly 3 of 9 Horn Installation 1995 Through 2003 Models 1 Cut the cable strap securing the horn wire lead s to the frame Remove the horn wire s from the wire bundle Secure the remaining wires to the frame with a new cable strap 26 from the kit 2 Route the horn wires with terminal clips from the front mounted horn down behind the engine center mounting bracket for later installation to the new side mounted chrome horn kit 3 Refer to HORN REMOVAL in the Service Manu2. 7041 15 Acorn nut high crown 5 16 18 7527 16 Bracket enrichener cable for 1995 2003 models 69035 95 17 Bracket assembly horn and enrichener cable for 2004 and later models 16355 04 18 Flat washer 1 12 in 28 4 mm O D 2 6237 19 Engine center mounting bracket for 2007 and later models 16353 04 20 Cap screw hex socket head 3 8 16 x 1 1 4 in long 2 4748 21 Flat washer hardened 0 78 in 19 8 mm O D 2 6787 22 Screw hex socket button head 10 32 x 1 2 in long with lock patch 3026 for 2007 and later models 23 Cap screw hex head 5 16 18 x 3 in long for 1992 models 4086A 24 Cap screw hex head 5 16 18 x 3 5 8 in long for 1993 2003 models 4116 25 Cap screw hex socket head 5 16 18 x 4 1 4 in long for 2004 and later models 4771 26 Cable strap double loop 2 10081 Items mentioned in text but not included in kit A Rear cylinder head top motor mount bolt and washer J03042 8 of 9 vice Parts Chrome Horn Kit Figure 10 Ser of 9 J03042
3. 8 models Enrichener bracket Item 16 8 See Figure 6 Position the new enrichener bracket 1 if used to the engine center mounting bracket 2 4of9 Enrichener bracket Engine center mounting bracket Enrichener cable nut Rubber horn mount Rear cylinder head top motor mount screw Horn assembly Lock washer Acorn nut ONO Pena Figure 6 Horn Assembly Installation 1995 2003 Models NOTE Turn the nut on the back of the enrichener cable counterclock wise to tighten 9 10 11 12 13 14 Install the enrichener cable to the center engine mount bracket 2 or new enrichener bracket Tighten the enrichener cable nut 3 securely Install the rubber horn mount 4 onto the center engine mount bracket or enrichener bracket with the 5 16 18 flanged locknut from the kit Tighten the nut to 60 180 in Ibs 6 7 20 3 Nm Obtain the horn and chrome cover assembled earlier Install the ground wire from the kit to the ground terminal on the horn Route the ring terminal end of the ground wire to the rear cylinder head top motor mount screw 5 Remove the screw and slip the ring terminal onto the screw threads Install the screw and tighten to 25 30 ft Ibs 34 41 Nm Position the horn assembly 6 onto the rubber mount 4 stud Install the lockwasher 7 over the stud Secure the assembly with the acorn nut 8 from the kit Tighten to 60 180 in Ibs 6 7 20 3 Nm Connect the horn w
4. LLATION in the Service Manual Tighten the fuel tank front mounting screw to 96 192 in lbs 10 8 21 6 Nm See Figure 10 and Table 1 Obtain the following items from the kit Rubber horn mount Item 11 5 16 18 flanged locknut Item 12 Ground wire Item 13 Split lockwasher 5 16 in Item 14 Acorn nut high crown 5 16 18 Item 15 Horn and enrichener cable bracket Item 17 2 1 12 in 28 4 mm diameter flat washers Item 18 Engine center mounting bracket Item 19 2 3 8 16 x 1 1 4 in long socket head cap screw Item 20 2 3 4 in 19 mm diameter hardened flat washers Item 21 2 10 32 x 1 2 in long button head screw Item 22 See Figure 9 Remove the two button head screws 1 with lock washers found in the cylinder head holes 2 Position the new engine center mounting bracket 3 over the holes and secure with the two 3 8 16 x 1 1 4 in long socket head cap screws 4 and hardened flat washers 5 from the kit Tighten the screws to 17 24 ft lbs 23 0 32 5 Nm Position the horn mounting bracket 6 over the engine center mounting bracket and secure with the two 10 32 x 1 2 in long button head screws 7 from the kit Tighten the screws to 36 60 in Ibs 4 7 Nm Install one of the large diameter flat washers 8 on each threaded stud of the rubber mount 9 Insert a rubber mount stud through the slot in the horn bracket and secure from behind with the 5 16 18 flanged locknut 10 from the kit Tighten the n
5. Through 1994 Models 1 Cut the cable strap securing the horn wire lead s to the frame Remove the horn wire s from the wire bundle Secure the remaining wires to the frame with a new cable strap 26 from the kit Route the horn wires with terminal clips from the front mounted horn down behind the engine center mounting bracket for later installation to the new side mounted chrome horn kit Refer to HORN REMOVAL in the Service Manual and follow the instructions for removing the O E front mounted horn assembly for your model For 1992 models Obtain the 5 16 18 x 3 in hex head cap screw 23 from the kit For 1993 and 1994 models Obtain the 5 16 18 x 3 5 8 in hex head cap screw 24 from the kit AWARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 5 Install the fuel tank to the vehicle using the new screw obtained in Step 4 and the remaining hardware removed earlier Refer to FUEL TANK INSTALLATION in the Ser vice Manual Tighten the fuel tank front mounting screw to 96 192 in Ibs 10 8 21 6 Nm 2of9 is04055 Enrichener cable nut Enrichener cable bracket Ignition switch housing nut Engine center mounting bracket Hex socket head bolt oP ONS Figure 3 Original Enrichener Bracket 1992 1994 Models NOTE Turn the nut on the b
6. ack of the enrichener cable clockwise to loosen 6 See Figure 3 Loosen the nut 1 on the back of the enrichener cable Remove the cable from the enrichener bracket 2 and let it hang free Loosen the ignition switch housing lock nut 3 on the underside of the engine center mounting bracket 4 Remove the hex socket head bolt 5 and the original equipment enrichener bracket from the top of the engine center mounting bracket See Figure 10 and Table 1 Obtain the following items from the kit Horn and enrichener cable bracket Item 9 3 8 16 x 5 8 in long button head screw Item 10 Rubber horn mount Item 11 5 16 18 flanged locknut Item 12 Ground wire Item 13 Split lockwasher 5 16 in Item 14 Acorn nut high crown 5 16 18 Item 15 See Figure 4 Install the new horn and enrichener cable bracket 1 to the engine center mounting bracket 2 using the new screw 3 Tighten the screw to 60 120 in Ibs 6 8 13 6 Nm J03042 Horn and enrichener cable bracket Engine center mounting bracket Button head screw Enrichener cable nut Rubber horn mount Rear cylinder head top motor mount screw Horn assembly Lockwasher Acorn nut DON OO BO Ne Figure 4 Horn Assembly Installation 1992 1994 Models 10 Tighten the ignition switch housing lock nut loosened in Step 7 to 6 ft lbs 8 Nm NOTE Turn the nut on the back of the enrichener cable counterclock wise to tighten 11 12 13
7. al and follow the instructions for removing the O E front mounted horn assembly for your model 4 Obtain the 5 16 18 x 3 5 8 in hex head cap screw 24 from the kit Install the fuel tank to the vehicle using the new screw and the remaining hardware removed earlier Refer to FUEL TANK INSTALLATION in the Service Manual Tighten the fuel tank front mounting screw to 96 192 in Ibs 10 8 21 6 Nm NOTE Turn the nut on the back of the enrichener cable clockwise to loosen 5 See Figure 5 Loosen the nut on the back of the enrichener cable Remove the cable from the slot 3 in the enrichener bracket 1 1995 through 1998 models or center engine mount bracket 2 1999 through 2003 models and let it hang free J03042 is04064 gi Enrichener bracket Center engine mount bracket Enrichener cable slot Acorn nut Flat washer Enrichener cover SEO OTRO Dt Carriage bolt Figure 5 Original Enrichener Bracket 1995 2003 Models 6 Remove and discard the acorn nut 4 and flat washer 5 retaining the black plastic enrichener cover 6 Discard the cover Remove and discard the carriage bolt 7 and the enrichener bracket 1 if so equipped 7 See Figure 10 and Table 1 Obtain the following items from the kit e Rubber horn mount Item 11 e 5 16 18 flanged locknut Item 12 e Ground wire Item 13 e Split lockwasher 5 16 in Item 14 e Acorn nut high crown 5 16 18 Item 15 e For 1995 through 199
8. cMOTOR HARLEY DAVIDSON WY J03042 INSTRUCTIONS REV 2014 03 13 CHROME HORN KIT GENERAL Kit Number 69112 95E 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 Additional Parts Required Loctite 243 Blue Threadlocker and Sealant H D Part Number 99642 97 is needed for the proper installation of this kit IWIN NIN 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 Preparation 1 2007 and later models Refer to the Service Manual and follow the procedures under FUEL TANK PURGING AND DISCONNECTING THE FUEL LINE ALL models IWAN IN To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a J03042 amp Many Harley Davidson Parts amp Accessories are made
9. from the mounting stud 1 of the new horn 5 from the kit Assemble the chrome horn cover 4 onto the horn using the middle hole in the horn cover bracket 6 as shown Install the internal tooth lockwasher 2 from the kit onto the horn mounting stud Apply 1 2 drops of Loctite 243 Blue to the threads of the flanged hex nut and install the nut to the horn mounting stud Tighten the nut to 110 in Ibs 12 3 Nm 6 Push the two speed nuts 7 from the kit over the holes in the top and bottom ears of the horn cover bracket 1 of 9 Please dispose of materials responsibly See Figure 2 Align the horn mounting bracket 1 over the speed nuts on the horn cover bracket 2 Install one of the flanged hex head screws 3 from the kit through the bottom speed nut Insert the remaining screw 4 through the hole in the horn wire clip 5 and secure the screw to the top speed nut Tighten the screws to 5 8 in Ibs 56 90 Nm Continue with Horn Installation for the correct year vehicle is04028 Horn cover bracket Speed nut clip nut 2 1 Horn mounting stud 2 Lockwasher 3 Hex nut 4 Horn cover chrome 5 Horn 6 7 Figure 1 Horn Cover and Hardware All Models J03042 is04029 Horn mounting bracket Horn cover bracket Flanged hex head screw bottom Flanged hex head screw top Horn wire clip Si No Figure 2 Horn Mounting Bracket Installation Horn Installation 1992
10. ire terminal clips from the main wire harness to the spade connections on the new horn Pro ceed to Final Assembly Horn Installation 2004 Through 2006 Models 1 Cut the cable strap securing the horn wire lead s to the frame Remove the horn wire s from the wire bundle Secure the remaining wires to the frame with a new cable strap 26 from the kit J03042 Route the horn wires with terminal clips from the front mounted horn down behind the engine center mounting bracket see Figure 7 Items 4 and 5 for later installation to the new side mounted chrome horn kit Refer to HORN REMOVAL in the Service Manual and follow the instructions for removing the O E front mounted horn assembly for your model Obtain the 5 16 18 x 4 1 4 in hex head cap screw 25 from the kit Install the fuel tank to the vehicle using the new screw and the remaining hardware removed earlier Refer to FUEL TANK INSTALLATION in the Service Manual Tighten the fuel tank front mounting screw to 96 192 in Ibs 10 8 21 6 Nm NOTE Turn the nut on the back of the enrichener cable clockwise to loosen 5 See Figure 7 Loosen the nut 1 on the back of the enrichener cable Remove the cable from the slot in the enrichener bracket 2 and let it hang free is04032 1 Enrichener cable nut 2 Enrichener bracket 3 Button head screw 2 4 Engine center mounting bracket 5 Horn wire path Figure 7 Original Enrichener Bracke
11. me cover 5 assembled earlier Install the ground wire from the kit to the ground terminal on the horn Route the ring terminal end of the ground wire to the rear cylinder head top motor mount screw Remove the screw and slip the ring terminal onto the screw threads Install the screw and tighten to 25 30 ft lbs 34 41 Nm Position the horn assembly onto the rubber mount stud Install the lockwasher 7 over the stud Secure the assembly with the acorn nut 6 from the kit Tighten to 60 180 in Ibs 6 7 20 3 Nm Connect the horn wire terminal clips from the main wire harness to the spade connections on the new horn Pro ceed to Final Assembly Horn Installation 2007 and Later Models 1 Cut the cable strap securing the horn wire lead s to the frame Remove the horn wire s from the wire bundle Secure the remaining wires to the frame with a new cable strap 26 from the kit Route the horn wires with terminal clips from the front mounted horn down between the cylinder heads on the left side of the vehicle for later installation to the new side mounted chrome horn kit J03042 10 Refer to HORN REMOVAL in the Service Manual and follow the instructions for removing the O E front mounted horn assembly for your model Obtain the 5 16 18 x 4 1 4 in hex head cap screw 25 from the kit Install the fuel tank to the vehicle using the new screw and the remaining hardware removed earlier Refer to FUEL TANK INSTA
12. of plastics and metals which can be recycled WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a e For 2004 and later models the negative battery cable is most easily disconnected at the engine crankcase N Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first Retain all seat mounting hardware WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 3 Remove the fuel tank from the vehicle Refer to FUEL TANK REMOVAL in the Service Manual The original equipment O E hex head screw that secured the front of the fuel tank can be discarded Retain all other fuel tank components and hardware for re assembly 4 See Figure 10 and Table 1 Obtain the following items from the kit e Horn assembly Item 1 e Chrome horn cover assembly Item 3 e 2 speed nuts Item 4 e 5 16 in internal tooth lockwasher Item 5 e Horn mounting bracket Item 6 e 2 1 4 20 x 3 8 in long flanged hex head screws Item 7 e Wire clip Item 8 5 See Figure 1 Use a 10 mm wrench to remove the flanged hex nut 3
13. rminals Use recommended torque values Over tightening battery ter 00216a minal bolts could result in damage to battery terminals 3 Apply a light coat of petroleum jelly or corrosion retardant AWaRrNING eke i he material to the battery terminals Refer to the Service Connect positive battery cable first If positive cable should contact ground with negative cable connected Manual and follow the instructions given to re attach the battery cables positive cable first the resulting sparks can cause a battery explosion which 4 Test the horn assembly for proper operation could result in death or serious injury 00068a SERVICE PARTS Table 1 Service Parts Table Item Description Quantity Part Number Horn trumpet includes Item 2 Not sold separately 2 e Nut hex flanged M6 1 0 7495 3 Horn cover assembly chrome 61300478 4 Speed nut 1 4 20 2 8108 5 Lockwasher internal tooth 5 16 in 7127 6 Bracket horn mounting 69120 91 7 Screw hex head large serrated flange 1 4 20 x 3 8 in long 2 3563 8 Wire clip vinyl coated 69062 91A 9 Bracket assembly horn and enrichener cable for 1992 1994 models 69027 92 10 Screw hex socket button head 3 8 16 x 5 8 in long 2916 11 Rubber horn mount 69123 92 12 Locknut flanged 5 16 18 7531 13 Ground wire horn 70087 95 14 Lockwasher helical spring 5 16 in
14. t 2004 2006 Models 6 Remove and discard the enrichener mounting bracket Save the two button head screws 3 See Figure 10 and Table 1 Obtain the following items from the kit Rubber horn mount Item 11 5 16 18 flanged locknut Item 12 Ground wire Item 13 Split lockwasher 5 16 in Item 14 Acorn nut high crown 5 16 18 Item 15 Horn and enrichener cable bracket Item 17 2 1 12 in 28 4 mm diameter flat washers Item 18 See Figure 8 Position the new horn and enrichener cable bracket 1 over the engine center mounting bracket and secure with the two button head screws saved in step 6 Tighten the screws to 36 60 in Ibs 4 7 Nm 5 of 9 Install one of the large diameter flat washers 2 on each threaded stud of the rubber mount 3 Insert a rubber mount stud through the slot in the enrichener bracket and secure from behind with the 5 16 18 flanged lock nut from the kit Tighten the nut to 60 180 in Ibs 6 7 20 3 Nm is04033 a 1 Horn and enrichener cable bracket 2 Flat washer 2 3 Rubber horn mount 4 Enrichener cable 5 Horn and chrome cover assembly 6 Acorn nut 7 Lockwasher Figure 8 Horn Assembly Installation 2004 2006 Models NOTE Turn the nut on the back of the enrichener cable counterclock wise to tighten 10 11 12 13 14 Install the enrichener cable 4 to the enrichener bracket Tighten the enrichener cable nut securely Obtain the horn and chro
15. ut to 60 180 in Ibs 6 7 20 3 Nm Obtain the horn and chrome cover 11 assembled earlier Install the ground wire from the kit to the ground terminal on the horn 6 of 9 eg Button head screw 2 Cylinder head hole 2 Engine center mounting bracket 3 8 16 socket head cap screw 2 Hardened flat washer 2 Horn mounting bracket 10 32 button head screw 2 Flat washer 2 Rubber horn mount 10 5 16 18 flanged lock nut 11 Horn and chrome cover assembly 12 Lock washer 13 Acorn nut CON OOP eh Figure 9 Horn Assembly Installation 2007 and Later Models J03042 11 12 13 Route the ring terminal end of the ground wire to the rear cylinder head top motor mount screw Remove the screw and slip the ring terminal onto the screw threads Install the screw and tighten to 25 30 ft Ibs 34 41 Nm Position the horn assembly onto the rubber mount stud Install the lockwasher 12 over the stud Secure the assembly with the acorn nut 13 from the kit Tighten to 60 180 in Ibs 6 7 20 3 Nm Connect the horn wire terminal clips from the main wire harness to the spade connections on the new horn Pro ceed to Final Assembly 7 0f9 FINAL ASSEMBLY 1 Using a cable strap from the kit secure the excess horn wire to the main wiring harness under the tank 2 Verify that the Ignition Light Key Switch is turned to the OFF position NOTICE Do not over tighten bolts on battery te
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