INSTRUCTIONS - Harley
Contents
1. HARLEY DAVIDSON J00835 INSTRUCTIONS REV 3 27 00 Kit Number 77165 98 1998 FLHT C CRUISE CONTROL KIT GENERAL This cruise control kit is designed for installation on 1998 and later FLHT C model motorcycles See Service Parts for kit contents Awarnine Harley Davidson Inc recommends that this kit be installed by a Harley Davidson authorized dealer Improper installation could cause cruise control malfunction loss of control and death or serious injury Service Manual Required This Instruction Sheet refers the installer to the appropriate FLT Service Manual for many procedures Therefore Harley Davidson recommends that you do not attempt to install this kit without having a copy of the FLT Service Manual applicable to your vehicle NOTE A Service Manual for your vehicle is available from your Harley Davidson dealer INSTALLATION 1 Review the CRUISE CONTROL Ultra MODELS section in the applicable FLT Service Manual before attempting to install this kit NOTE When connector numbers such as 22A are referenced they identify connectors on wiring diagrams Wiring diagrams are located at the rear of the FLT Service Manual on Wiring Diagram Wallcharts and in the Electrical Troubleshooting Manual Cruise Control Module WARNING To avoid personal injury do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components Gasoline2. 6351 96 Washer approx 5 8 in O D 6047 Cruise cable 56372 98 Conduit 1 4 in x 12 in long 63574 94 Plugs lock 4 Int l only 90468 95 Washer approx 3 8 in O D 6717 Wire harness retainer 70345 84 13 Wire harness retainer 56073 83 2 into 1 wire terminal 9938 14 Cruise Module 70989 98A Wire 16 in long O W 70652 99 15 Cruise ON OFF switch 71513 98 Terminal socket 2 72191 94 Ring retaining 11193 not shown in illustration J00835 8 of 8
3. ce Manual instructions to connect cruise cable to carburetor 9 See Figure 2 Install wire harness retainer on cruise cable and insert barb on clip into hole in frame On Calif models remove EVAP hose from cable clip and secure hose with T stud cable strap from kit in location shown Idle Control Cable Throttle Adjusting Screw 1 Remove outer fairing following the applicable Service Manual procedures 2 Disconnect stock idle control cable from carburetor following instructions in Service Manual 3 Remove upper and lower right handlebar switch housing screws 4 See Figure 4 Loosen throttle adjusting screw 1 and remove friction spring 2 from groove in switch housing 3 5 Remove retaining ring 4 from throttle adjusting screw 1 and remove spring 5 and screw 1 from lower switch housing 3 6 Plug throttle adjusting screw tapped hole in switch housing 3 with pop rivet 6 and washer 7 7 Discard throttle adjusting screw spring retaining ring and friction spring 1of8 Cruise module mounting holes Left side of battery box Figure 1 Cruise Module Mounting Holes 8 Remove idle control cable brass ferrule from notch in throttle grip Retain brass ferrule for use later 9 Follow instructions in Section 2 of applicable Service Manual to remove stock idle cable 10 Follow instructions in Section 8 CRUISE CONTROL THROTTLE CABLES of applicable Service Manual and install the new idle co
4. e existing O W wire from back of cigarette lighter connect O W from Set Resume switch to lighter then reconnect original O W wire to spade on 2 into 1 terminal Cruise Control Harness Installation 1 See Figure 12 The cruise control harness electrical connections are shown 2 Refer to CRUISE HARNESS Installation in applicable Service Manual and install cruise control harness following the instructions given NOTE The 3 place socket connector containing orange blue black green and red orange wires is only used on Ultra models Secure the 3 place connector to frame tube behind cruise module with cable strap 3 Install cable straps at the locations specified in the CRUISE HARNESS Installation procedure in the Service Manual 4 Check that all wires and harnesses are located away from hot or moving parts J Clamp and Throttle Cable 1 See Figure 13 Using the sharp edge of a knife carefully pull out the plastic plug in forward area of frame i00300 Screw and washer 2 Master cylinder clamp Master cylinder Escutcheon Switch Speednut Handlebar clamp Tabs wire end of switch i00721a Stock Washers and 1 4 20x1 5 8 Screws from kit Handlebar Clamp Set Resume Switch Figure 8 Set Resume Switch Attachment 2 See Service Parts illustration Install well nut 9 from kit in hole Install flat washer 10 and J clamp 1 on screw Start screw into well nut With the loop o
5. es Location Connector 105B 3 Insert switch 6 with side having two tabs 7 positioned as shown 4 Press switch 6 into escutcheon 4 until it latches into position 5 Install speednut 8 place actuator 9 on switch rod and press until actuator pins enter holes in switch tabs 10 Set Resume Switch Attachment to Handlebar Clamp 1 Cut the cable strap securing harnesses to right handlebar 2 Route the Set Resume harness along the handlebar and forward of the inner fairing A E gt Switch Hole 3 Replace cable strap with one from kit 4 Plug pi aF A Pa 4 See Figure 8 Attach handlebar clamp to master cylinder Figure 6 On Off Switch Location 1996 and Later with the stock washers and two 1 4 20 x 1 5 8 in hex socket button head screws from kit Set Resume Switch Placement Into Handlebar Clamp Set Resume Switch Electrical Connections 1 Cut connectors off ends of Blue Black wires Following CAUTION instructions in Service Manual under Deutsch Electrical Do not disconnect or remove the switch housing Connectors crimp sockets P N 72191 94 onto each assembly without first placing a 5 32 inch thick cardboard wire end insert or cable strap eyelet between the brake lever and 2 Install Set Resume switch wires into cavities 11 and 12 of lever bracket Housing removal without an insert may connector 22 as follows see Figure 11 for connector result in damage to the rubber boot and plunger of the locati
6. f the clamp orientated at the top tighten the clamp screw until snug 3 Position the throttle control and idle control cables within the J clamp Pinch or press ends of clamp closed to contain cables Adjust Throttle Idle and Cruise Control Wire Harness 1 Refer to the CRUISE CONTROL THROTTLE CABLES section in Section 8 of the applicable Service Manual and adjust the throttle idle control cable and cruise cables 2 Perform cruise cable adjustment See Cable Lash Initialization in applicable Service Manual i00292 9 Actuator 10 Tabs actuator 2 11 Harness Figure 9 Installing Set Resume Switch J00835 5 of 8 FINAL CHECK AND TEST RIDE 1 Check that all connections have been made and that all wiring is properly secured with cable straps N Perform the Switch Diagnostic Sequence in the applicable Service Manual before installing fuel tank outer fairing left side cover and left saddlebag WARNING 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 death or serious injury 3 To perform the tests reconnect battery positive cable first WARNING To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the fol
7. is extremely flammable and highly explosive under certain conditions WARNING To avoid accidental start up of motorcycle and possible personal injury disconnect the battery cables negative cable first before performing any of the following procedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in death or serious injury 2 Remove battery left saddlebag left sidecover fuel tank and air cleaner assembly following instructions in applicable Service Manual 3 See Figure 1 Identify mounting holes for cruise control module on left side of battery box 4 See Service Parts illustration Place grommets 6 through holes shown in Figure 1 with large diameters on inside of battery box NOTE The cruise cable will be installed on the cruise module in the kit If cable is removed refer to applicable Service Manual for correct reinstallation procedure 5 See Figure 3 While feeding cruise cable and adjuster through hole in frame cross member place cruise module 1 in position shown 6 See Service Parts illustration Install three flange nuts 17 to secure cruise control module to box Tighten nuts to 9 11 ft lbs 7 From left side of motorcycle route the cruise cable under rear cylinder spark plug wire forward above top engine stabilizer and then down between cylinder heads and right to carburetor 8 Follow Servi
8. k O o p ZEA A Q aaa Cr O B a Cigarette F lighter Figure 11 Cruise Harness Connections At Inner Fairing J00835 6 of 8 i01062 o TO INTERCONNECT HARNESS 6A SNWORUANO TO LEFT GROUND STUD O UNDER SEAT 92D uN 92C HROTE CRUISE CONTROL RLO OD HARNESS SWITCH Part No 77141 98 Figure 12 Electrical Connections 100302 Steering head Frame backbone Plastic plug am Figure 13 Remove Plug From Frame J00835 7of8 aim Part No 77165 98 Date 3 00 K Service Parts 1998 Cruise Control Kit sp77166 98 a Description Part No Description Part No Clamp J type 10003 Decal ign switch 71537 96 Cable straps 5 in 11 10039 Flange nuts 3 7499 Cable straps 15 in 3 10073 Rivet pop 8625 T stud clip strap CA models 10133 Screw machine truss 933 Butt splice connector 70585 93 Cruise control wire harness 70141 98 Grommets 3 11497 not used Screws 1 4 20 x 1 5 8 in 2 4033 not used Handlebar master cylinder clamp not used with Set Resume switch hsng 45043 89 Switch Set Resume 77163 94 Nut well 5207 Idle control cable 5
9. lowing procedures If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion resulting in death or serious injury Wire seal WIRE COLOR CAVITY White blue 11 Blue Black 12 4 After tests are completed disconnect battery negative cable first 5 Install fuel tank air cleaner backplate air cleaner filter and cover left side cover outer fairing and left saddlebag WARNING 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 death or serious injury 6 Connect battery positive cable first 7 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 causing loss of control and death or serious injury 8 Refer to cruise control section in Owner s Manual for cruise control operating instructions 9 Test ride motorcycle and verify cruise control is operating properly Locking wedge Figure 10 Set Resume Switch Connections 103023 Cruise harness to Set Resume interconnect switch harness connector 22 connector 6 T 6 3 o 0 oo o o IE aA I
10. ntrol cable from kit 11 Do not adjust throttle and idle cables now The throttle idle and cruise cables will be adjusted after cruise control harness installation Wess Cruise module old style shown Cruise cable Connector latch Cruise connector 17B Selita 100998 T stud for attaching EVAP hose on Calif models Rear cylinder head Cable clip Figure 2 Attaching Cruise Cable Adjuster Left Side View 12 See Figure 5 Install the coiled tubing on the throttle cable from front to rear Open the split in the tubing place the tubing on the cable and feed tubing back through the frame clamp until the tubing end contacts the induction module cable guide AN i Mil h Il M M s J P Figure 3 Mounting Cruise Module J00835 2of8 Cruise Control ON OFF Switch NOTE Cruise control ON OFF switch installs in fairing cap right side next to ACC switch Removal of ignition switch on International models requires removing switch position decal and tamper proof plugs See applicable Service Manual for detailed REMOVAL INSTALLATION instructions 1 See Figure 6 Remove ignition switch and fairing cap according to Service Manual instructions 2 See Figure 7 Remove screws 1 holding switch bracket 2 in place 3 Remove switch hole plug 4 Install cruise control switch wires through bracket Place cruise switch in opening of bracket and engage tabs on switch into slots on b
11. on pent Brake light ewite See Figure 10 Remove the connector s secondary 1 See Figure 9 Remove the two screws and washers 1 locking wedge Grasp each crimped pin approximately 1 that secure the master cylinder clamp 2 and master inch behind the contact barrel Gently push pins through cylinder 3 to the handlebar and remove master cylinder holes in wire seal into their respective locations shown in clamp 2 Discard the two screws and retain the washers figure Feed each pin into chamber until it clicks in place for use later NOTE 2 Remove from the kit and insert the escutcheon 4 into f secondary locking wedge does not slide into position easily the Set Resume handlebar clamp 5 verify that all terminals are fully inserted into the housing i03056 eps Speaker switch Ultra models only 1 Screws 2 4 ACC switch 2 Bracket 5 Cruise ON OFF switch 3 Socket housing 105B Figure 7 Fairing Cap Switches Ultra shown J00835 4of8 3 Connect power wire O V of Set Resume switch to cigarette lighter as follows a Cut connector off of end of O V switch wire b Follow procedures under Sealed Butt Splice Connectors in Service Manual to connect O W wire in kit item 30 to O V wire of Set Resume switch using heat sealed connector in kit item 5 c Crimp 2 into 1 terminal in kit item 29 onto end of O W wire and route wire to cigarette lighter see Figure 11 for location of lighter d Remov
12. racket latches CAUTION Make certain socket terminals are correctly oriented in the next step The slot and crimp tails must face toward the release button on the socket housing Any other orientation will not allow terminal to lock in position 5 Refer to FAIRING CAP SWITCHES in applicable Service Manual Open secondary lock on 12 place socket housing 105B located behind the fairing cap Connect the Orange Violet wire to cavity number 4 Connect the Red Green wire to cavity number 5 Connect one Black Green wire to cavity number 12 in the 12 place socket housing Terminate the 2nd Black Green wire it is not used i00303 i00295 1 Throttle adjust screw Friction spring Lower right switch housing Retaining ring Spring Pop rivet Washer Figure 4 Throttle Adjusting Screw and Tapped Hole 6 Close secondary lock on socket housing 7 Place Accessory and Cruise switches in fairing cap openings Install screws holding switch bracket NOTE Do not install fairing cap or ignition switch now ee ae Cruise control harness Throttle cable N S inn Roll off switch wires inboard of throttle amp idle cables I ae Coiled tubing Idle cable Roll off switch wire connections Figure 5 Throttle Idle Cable and Roll off Switch Configuration J00835 3 of 8 Ignition Switch Fairing Switch
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