Halogen Bulb Kit for Auxiliary Lamps
J036382013-11-01
GENERAL
Kit Number
68208-98A
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 2 and Table 1.
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.
INSTALLATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
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)
1.
See the Service Manual. Remove the seat and disconnect battery negative cable first.
2.
Remove the screw that holds the auxiliary lamp bezel ring in place and remove the bezel ring. Disconnect wires from back of bulb and remove bulb from housing.
3.
Cut the terminals off the two wires leading from the bulb housing to the bulb as close as possible to the terminals. The negative lead (ground) is the BLACK wire attached to the bulb housing. The positive lead is the GRAY (or gray/black) wire that exits through the bottom of the lamp.
NOTE
On 2006 and later Touring models and 2006 and later FLSTC models originally equipped with auxiliary lamps, go to step 4.
On 2005 and earlier Touring models and 2005 and earlier FLSTC models originally equipped with auxiliary lamps, go to step 7.
4.
Obtain wire provided in auxiliary lamp kit and cut into four equal length pieces.
5.
Strip 1/4 in. (6.35mm) of insulation off one end of each of the wires cut. Using butt connectors included in kit, splice a wire to each lead inside lamp housing.
6.
Install heat shrink tubing over each wire splice.
1Insulation crimp
2Core crimp
3Terminal tab
4Spring release
Figure 1. Kit Terminals
7.
See Figure 1. Compare the two spade terminals in kit. The smaller terminal will be installed on the negative lead. The larger terminal, which has a spring release, will be installed on the positive lead. Before installing terminals, take the smaller terminal (for the negative lead) and grasp the small tab (3) at the end of the terminal with pliers. While holding the terminal tab, move the terminal back and forth to break off the tab. This will allow the terminal to slide completely onto the negative post of the new bulb (the post located between the two adjacent screws on the back of the bulb).
8.
See Figure 2. Slide terminal housing (3) over positive lead. Strip 1/4 in. (6.35mm) of insulation off the end of each wire.
9.
Using the correct die on crimp tool, crimp the spade terminal core (2) and then the insulation (1) to make a proper terminal attachment as shown in Figure 1. Do this for the positive and negative terminals. Snap terminal housing in place over positive lead spade terminal.
10.
On the bottom of the rubber boot, there is a rectangular slot. The white wire exits through this slot in the rubber boot on the passing lamp. Also, inside the slot is the ground wire connection post. Push the gray (or gray/black) wire terminal onto the white wire terminal until it clicks. Then push the black wire terminal onto the ground post inside the boot.
NOTE
The ground wire terminal will only attach in one direction. If strong resistance is felt, flip the terminal over and try again.
11.
Place bulb and wires back into housing, place ring over bulb and housing, and tighten screw to hold bulb in place.
12.
Repeat steps 2 through 11 for the other side.
WARNING
Connect positive (+) 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. (00068a)
13.
Connect battery cables, positive cable first.
14.
Install seat.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
15.
Check auxiliary lamps for proper operation.
Service Parts
Figure 2. Service Parts
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Bulb assembly, halogen (2)
68847-98A
2
Spade terminal, + lead (2)
9849
3
Housing, spade terminal, + lead (2)
72049-92
4
Spade terminal, - lead (2)
72202-94
5
Tube, heat shrink (4)
67113-83
6
Butt splice (4)
70581-73
7
Extension, wire
Not sold