Filed Under (Harley Davidson) by admin on 20-04-2011
INSTALLATION Outer Fairing/Windshield and Auxiliary Lamp Bracket Removal To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2 3 1 2 is 01215 1. Six-position connector 2. Four-position connector 3. Auxiliary lamp connector Figure 1. Disconnect Signal and Auxiliary Lamp 1. Remove Maxi-Fuse. Refer to SYSTEM FUSES, MAXI- FUSE in Service Manual. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 2. Remove the windshield and outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual for the outer fairing/windshield removal procedure. 3. Disconnect auxiliary lamp and turn signal connectors. NOTE See Figure 1. On 2005 and prior year models, the left and right turn signals plug into a 6-place connector located on the left fairing support brace. On 2006 and later models, each turn signal plugs into its own 4-place connector located toward the bottom of the inner fairing on each side. 4. Using a T40 Torx® drive head, remove and save the four bolts securing the auxiliary head lamp bracket to the chassis. 5. Remove auxiliary lamp bracket from motorcycle. Turn Signal Assembly 1 is 01217 1. Triangular opening Figure 2. Insertion of Terminals Through Triangular Opening 1. See Figure 2. Insert wire terminals through the triangular opening in the turn signal mounting bracket included in the kit. 2. Fit turn signal housing onto bracket. 3. Apply a small amount of Loctite (243) blue (99642-97) to threads of hex head cap screw. 4. Tighten cap screw to 15-20 ft-lbs (20-27 Nm) . -J03753 1 of 2 Turn Signal Installation 1 is 01218 1. Turn signal wire Figure 3. Turn Signal Wire Routing 1. See Figure 3. Insert turn signal connector and wiring between bottom of fairing and top of outer fairing skirt. 2. Route turn signal wire under cutout on mounting bracket and place bracket onto motorcycle. NOTE Care must be taken so the turn signal wire is not pinched between turn signal bracket and motorcycle chassis. 3. Install washers onto turn signal bracket mounting bolts and apply Loctite 243 (blue) (99642-97) to the bolt threads. 4. Tighten mounting bolts to 15-20 ft-lbs (20-27 Nm) . 5. Route turn signal leads toward harness connector. Secure loose wiring with tie straps so wires do not rub against any sharp objects
Filed Under (Harley Davidson) by admin on 08-03-2011
INSTALLATION Prepare the Motorcycle 1. Remove the right cover and the maxi-fuse. 2. Follow Service Manual instructions to remove the air box cover. Remove the Existing Rear Turn Signals 1. For 2006 and Earlier Models: See Figure 1. Insert a screwdriver into middle of hole of license plate light cover. Push forward to release tail lamp housing retaining clip. 2. See Figure 3. Identify the white left  (1) and black right  (2) 2 pin rear turn signal connectors. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. To remove the rear turn signal wires from the socket terminal housing, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. 6. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 7. Repeat for the opposite turn signal. 1. For 2007 and Later Models: See Figure 2. Open seat and remove the nut and washer (3), seat post (2), passenger pillion and passenger seat (1) per the instructions in the Service Manual. 2. See Figure 4. Identify the left (1) and right (2) rear turn signal wires and 6 pin rear turn signal connector . 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. See Figure 5. Remove the turn signal wires from the 6 pin socket terminal housing. To remove the wires, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. Repeat for all four turn signal wires. Do not remove the license light wires from the socket terminal housing. 6. Gently pull the loose turn signal wires through the sheath toward the rear of the vehicle until completely removed from the sheath. 7. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 8. Repeat for the opposite turn signal
Filed Under (Harley Davidson) by admin on 03-04-2012
STEP 1 Remove the stock mirrors. LEFT SIDE: STEP 2 Choose the longest Allen bolt from the hardware kit that passes through the hand control, a split lock washer, an internal tooth star washer, the turn signal mount (if applicable), and still provides maximum thread engagement in the mirror stem without bottoming out. Mount the mirror with the hardware listed above. (Place the star washer between the mirror stem and the hand control). RIGHT SIDE: STEP 3 If the turn signals are not mounted under the mirror, proceed in the same manner as the left side. STEP 4 If the turn signal is mounted under the mirror proceed as follows: Apply Red loctite to the short threaded end of the special mounting stud. Screw this end securely into the mirror stem. -cont.- 1432-22HD-0105 TURN SIGNAL MIRRORS WITH CONVEX GLASS 1432 INSTALLATION Illiana CUSTOMER SERVICE 877.370.3604 (toll free) INSTALLATION QUESTIONS firstname.lastname@example.org or call 715.247.2983 WARRANTY Küryakyn™warrants that any Küryakyn product sold hereunder, if properly installed, maintained and operated under normal conditions, shall be free from any defects in materials and workmanship for a period of one (1) year from the date the Küryakyn products are sold to the customer. CONSEQUENTIAL DAMAGES: Küryakyn shall not be liable for any consequential or incidental damages. ABOUTOURCA TA LOG You’ll find all our innovations for H-D, GL and Metric Cruisers in our annual catalogs. Order online today-select the “CATALOGS” icon. Each Küryakyn™ product comes with a Proof-of-Purchase good for a complimentary catalog. Details in packaging. Be sure to ask your local dealer about other Küryakynproducts, the motorcycle parts and accessories designed for riders by riders. ©2004 Küryakyn USA™All Rights reserved.
STEP 5 Remove the turn signal assembly from the stock mirror. Pay close attention to how the stock turn signal ball joint assembly comes apart as this will aid in re-assembly. STEP 6 Place a star washer over the mounting stud and insert the mirror and stud assembly into the hand control. Re-assemble the turn signal ball joint being sure the turn signal light is aimed to your liking. You may wish to consult your H-D shop manual when re-assembling this ball joint. WIRING: STEP 7 Determine where you wish to splice into the H-D turn signal wiring harness. Cut the harness or strip back an appropriate amount to vinyl wire covering and prepare the wires for splicing. Make the wire connections as follows: Wires from Turn Signal Mirror H-D Turn Signal Wire Colors Black – (Ground) Black (Ground) Red – (Running Light) Blue (Running Light) White (Turn Signal) Violet (Turn Signal) If a more pronounced flash is desired, one may eliminate the running light function and wire as follows: Black Black Red and White together Violet If these turn signal mirrors are to be used in conjunction with stock front turn signals, no load equalizer will be required. If the turn signal mirrors are REPLACING stock front turn signals, in most cases, a load equalizer is required. For easiest access we suggest installing the load equalizer under the seat; tapping into the main wiring harness that leads to the tail lights and rear turn signals.
Filed Under (Tips and Review) by admin on 09-11-2010
1. Place motorcycle on solid, level ground and on center stand if equipped. 2. Remove your turn signal lens. Place it upside down and clean the lens interior with the supplied alcohol wipe. Allow to completely air dry. Note: the LEDs are mounted to the inside of the turn signal lens with the LEDs making direct contact with the lens. The supplied silicone is used to secure the LED board to the lens. It remains flexible but can be removed. Test fit the board in your lens prior to using silicone. 3. Using a small screwdriver, poke a small hole in the end of the tube of silicone. Place a dab of silicone on each of the 12 LEDs on the circuit board. CAUTION : Note the position of the metal pins on the back of the LED board, They must be located 90 degrees from where the holes are that secure the lens to the housing. See attached diagram. 4. Position the round circuit board over the inside of your turn signal lens with the LEDs facing down. Get the board as centered as possible. Allow the silicone to make contact with the inside of the lens and then push down and slightly rotate the board back and forth to allow the LEDs to make contact with the lens surface. Repeat other side. NOTE : the silicone will require 30 minutes in 70 degree weather to tack up. Full cure will occur within 24 hours. We suggest not riding for several hours if possible to allow the best adhesion. 5. You will need to access the following wires; running light (license plate can be used), brake lights, right turn and left turn. Disassemble the bike as needed to gain access to the wiring. Shop Tip: we have found that on the Yamaha Star Series and the Kawasaki Cruisers that installation is much easier when you remove the turn signal bar from the fender. On the Yamahas, there are 3 bolts holding the moustache in position. The wires will unplug from behind the license plate. On the Kawasakis, unplug the signals under the seat and bend the tabs under the fender to be able to remove the wires. 6. We have provided some tubing to slide over the wires so that when you re-install the bulb socket, our wires for the LED boards will not be pinched. This tube should be slid all the way into the turn signal housing. You may have to shorten the tubing for your installation. 7. You will need to run wires through the stem of the turn signal. You can see samples of how the various manufacturers signal housings come apart on our web site. Click on “Other Lighting Products” and then “Turn Signal Conversion Kits” and follow the link. We suggest placing the removed turn signal assembly on a towel on your work area. 7. You will need to leave 2″ of slack in the wires at the turn signal housing to allow for wire connection. 8. Reinstall the turn signal housing back on the motorcycle if removed. NOTE: both of the run/brake circuits must be used. You may shorten the wires only on the run/brake circuits as needed. Do not change the circuits under the heat shrink. T-Tap instructions. Lay the “donor” wire in the slot in the burgandy connector. Close and snap together with pliars. Strip some insulation off of the wire which will be tapping into the factory wire. Crimp one of the pink connectors on the bare wire and plug it into the burgandy T-Tap 9. Connect the green wires from the run/brake circuits to the bikes running lights. The 2 greens can be connected together. 10. Connect the blue wires from the run/brake circuits to the bikes brake lights. The 2 blues can be connected together. 11. Take one of the red wires from a run/brake circuit and connect it to one of the black with white stripe wires coming from one of the LED boards using the supplied red butt connector. Connect the other run/brake circuit red wire to the remaining black with white stripe wire on the other LED board. 12. Connect the black wire from the LED board on the right side of the bike to the right turn signal positive (+) wire on the motorcycle. 13. Connect the black wire from the LED board on the left side of the bike to the left turn signal positive (+) wire on the motorcycle. 14. Plug the wires into the LED boards. If you hold the turn signal lens so that you are viewing the back of the LED board, position the connectors on the board at the 12 o’clock (top) position. The connector on the left is the positive (+) terminal. Connect the red wire to it. Connect the black wire to the remaining connector on the right side. 15. Check operation. LEDs should come on with running lights. LEDs will brighten when brake lights are applied. LEDs will shut off when the amber turn signal comes on. 16. Should you have any problems, please see the troubleshooting chart on our website.* * 17. Reassemble bike
Filed Under (Harley Davidson) by admin on 24-02-2011
REMOVAL 1. Remove seat according to the instructions in the Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) 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. (00049a) 2. See Figure 1. Disconnect battery cables, negative (-) cable first. 2 1 is03242 1. Negative (-) cable 2. Tail lamp connector Figure 1. Negative Battery Cable and Tail Lamp Connector 3. See Figure 2. Remove two screws and tail lamp lens (1) from base (2). 2 1 is03243 1. Tail lamp lens 2. Tail lamp base Figure 2. Remove Tail Lamp Lens 4. See Figure 3. Using a Terminal Pick Tool (1), depress locking tabs and disconnect turn signal connectors (2- place) (2, 3) from circuit board. 5. Feed turn signal wiring and connector through opening in circuit board assembly and into rear wheel area. 6. See Figure 4. Remove turn signal wiring (1, 2) from clips (3) under rear of fender INSTALLATION NOTE Proper installation of kit requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Route Turn Signal Wiring Through Rear Fender and Support 1. See Figure 5. Remove three rear screws (1) from fender support (2). 2. Loosen, but do not remove two front screws (3) from fender support. 1 3 2 is03285 1. Screw, rear (3) 2. Fender support 3. Screw, front (2) Figure 5. Fender Support Screws and Fender Support 3. Pull fender support away from rear fender to gain access to turn signal mount. 4. Remove stock screw and washer from turn signal mount. 5. See Figure 7. Pull turn signal (B) and turn signal mount (A) away from fender support. 6. Remove turn signal and wires from vehicle by routing turn signal wiring and connector through holes in rear fender and fender support. Gently guide wires through holes to ensure they do not get damaged. Feed Wiring and Install Relocation Bracket 1. See Figure 6. Feed turn signal wiring and connector through middle hole in turn signal relocation bracket and under rear of fender support. 1 is04635 1. Wire harness Figure 6. Wire Harness Routing 2. See Figure 7. Insert stock screw and washer through rear hole of relocation bracket (1) and turn signal mount (A). 3. Thread screw into turn signal (B). Tighten to 12-16 ft-lbs (16.3-21.7 Nm). 4. Align relocation bracket (1) with rear of fender support and install with screw (2) and nut (3) from kit. Tighten nut to 12-16 ft-lbs (16.3-21.7 Nm). Complete Turn Signal Relocation Wiring 1. See Figure 5. Install one rear screw (1) to hold fender support in place while routing wiring. Install screw snugly but do not fully tighten