Harley Davidson MC/ MIC HARNESS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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Use the diagonal cutters and razor blade to cut any tie wraps or harness coverings away from the harness connected to C28. At least 3 ” of wire must be unsheathed. Use a 1/16″ wide blade flat screw driver to push the Ampseal connector wedge lock tabs away from the red wedge lock as shown in Photo 3. Pull the wedge lock up as shown in Photo 4. The wedge lock should never be removed from the housing for insertion or removal of the contacts. Photo 3 – Connector Disassembly Step 1 Photo 4- Connector Disassembly Step 2 Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and 6): Grab the wire to be removed with needle nose pliers or hemostats. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Photo 5- Pin Removal, Step 1 Photo 6- Pin Removal, Step 2 End of Removal Technique
3 of 5 Document part number: 65298R2 Installing Kennedy Audio Interface Harness part #85582 Locate Kennedy harness part #85582 and 3 pieces of 1/8″ diameter x 2″ shrink-wrap. The sequence for installing the harness is: Locate and remove the appropriate contact from the Ampseal connector (refer to Figure 1, below). Place a piece of heat shrink over the corresponding mating pin on Kennedy harness #85582. Press the mating pin and the Ampseal connector contact together (See Photos 7 and 8)

HARLEY DAVIDSON DIRECTIONAL RELOCATION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect the negative (-) battery cable. INSTALLATION Installing the Turn Signal Stalk and Rear Docking Point 1. See Figure 3. Place the rear docking point (E) and recess cover (D) over the long threaded end of the new turn signal stalk (4) with the countersunk side of docking point facing outward. 2. Insert the turn signal stalk (4) through the rear mounting hole in the fender support and fender. Apply Loctite® 243 (blue) to the stalk and thread into fender mounting bracket. 3. Tighten the stalk to 12-18 ft-lb (16.3-24.4 Nm) . 4. Loosely install a jam nut (3) and a lockwasher (2) onto the short threaded end of the turn signal stalk (4). 5. Place the recess cover (1) into position over the recess on the turn signal housing. Insert the wires from the socket through the grommet into the turn signal housing, through the threaded hole and the recess cover, and into the turn signal stalk (4). NOTE Apply a drop of liquid soap to the wires to ease insertion through the stalk or use a thin wire to pull the wires through. 6. Route the wires through the turn signal stalk (4) until they are through the fender. 7. Install the turn signal housing onto the stud. Be careful that the wires are not twisted or damaged as the stalk and housing are assembled. The lockwasher will fit inside the hole in the recess cover. Hand-tighten the jam nut against the lockwasher. 8. While pulling the turn signal wires into the inside of the fender, guide the turn signal socket and grommet into the housing. 9. Align the rear turn signal housing so that when the lens is installed it is aimed rearward for proper visibility. While holding the turn signal housing in position, tighten the jam nut against the lockwasher to 8-10 ft-lb (10.8-13.6 Nm) . Connecting the Turn Signal Wires

HARLEY DAVIDSON 5-3/4 INCH HEADLAMP TRIM RING INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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These kits fit 1994 and later FXLR, FXST, FXSTC, FXSTB models, 1994 and later Dyna models, 2004 and later XL883, XL883L, XL883R, XL1200L, and XL1200R models and 2005 VRSCB model motorcycles. KIT CONTENTS See Figure 2 and Table 1. INSTALLATION 1. Loosen screw from the original equipment headlamp trim ring and remove ring. 2. Remove screw and nut from accessory trim ring assembly and set aside temporarily. 3. See Figure 1. If not already installed, place one rubber strip (2) inside trim ring (1) as shown. 4. See Service Parts Illustration. Insert the glass lens assembly (A) inside rubber strip (4) and trim ring (3), as shown. NOTE Rotating the lens may help insertion. 5. Install trim ring onto the main lamp housing (B). Assemble nut (2) and screw (1). Tighten securely

HARLEY DAVIDSON PASSING LAMP TRIM RINGS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Loosen the screw from one original equipment passing lamp trim ring and remove the ring. 2. See the Service Parts illustration. Remove the screw (3) and nut (2) from the accessory trim ring (1) and set aside temporarily. 3. If not already installed, place the rubber strip (4) inside the trim ring. Align so the gap in the rubber strip is opposite the split in the trim ring as shown. 4. Insert the passing lamp sealed unit (C) inside the new trim ring and rubber strip assembly. NOTE Rotating the lamp unit may help insertion. 5. Position the bottom of the lamp unit to line up with the split in the trim ring. 6. For 2002 and later models Install the adapter ring (D) onto the passing lamp housing, lining up the tab on the ring with the notch in the lamp housing. Install the trim ring and lamp assembly onto the adapter ring, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the adapter ring. For 1962 through 2001 models Install the trim ring and lamp assembly onto the passing lamp housing, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the passing lamp housing. 7. Assemble the screw and nut to the trim ring and tighten securely. 8. Perform steps 1 through 7 for the second passing lamp. SERVICE PARTS 4 2 B C F H 3 G E 1 A D

HARLEY DAVIDSON 5-3/ 4 INCH HEADLAMP TRIM RING INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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These kits fit 1994 and later FXLR, FXST, FXSTC, FXSTB models, 1994 and later Dyna models, 2004 and later XL883, XL883L, XL883R, XL1200L, and XL1200R models and 2005 VRSCB model motorcycles1. Loosen screw from the original equipment headlamp trim ring and remove ring. 2. Remove screw and nut from accessory trim ring assembly and set aside temporarily. 3. See Figure 1. If not already installed, place one rubber strip (2) inside trim ring (1) as shown. 4. See Service Parts Illustration. Insert the glass lens assembly (A) inside rubber strip (4) and trim ring (3), as shown. NOTE Rotating the lens may help insertion. 5. Install trim ring onto the main lamp housing (B). Assemble nut (2) and screw (1). Tighten securely. 1 2 is 01501 1. Trim ring 2. Rubber strip Figure 1. Installed Rubber Strip SERVICE PARTS See Figure 2 and Table 1