CUSTOM TOURING BULLET FRONT TURN SIGNAL KIT
J039862013-07-10
GENERAL
Kit Number
69577-06A (domestic) and 69578-06 (HDI)
Models
This fits 1996 and later FLHR, FLHRC and FLHRS models.
The kit is designed so that the auxiliary lamps and bracket (FLHR, FLHRC) and turn signal and bracket (FLHRS) will not be reused.
Additional Parts Required
Loctite® 243 (blue) (99642-97) is required for installation and is available from a Harley-Davidson dealer.
Kit Contents
REMOVAL
Remove Headlamp Assembly and Disconnect Wiring
2013 and Earlier Models
1Front turn signals connector [31]
2Accessory lamps connector [73] (FLHR/C only)
Figure 1. Headlamp Nacelle Connectors (FLHR/C/S)
  1. Refer to service manual and remove main fuse.
  2. See the service manual. Remove headlamp.
  3. See Figure 1. Inside headlamp nacelle, locate front turn signal lamps connector (1) and auxiliary lamps connector (2) (FLHR/C only).
  4. Disconnect front turn signal lamps connector and auxiliary lamps connector (FLHR/C only). Save connector(s) for later use.
  5. Remove pin terminals from connector housing(s). Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual for removing socket/pin terminals.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1.
2014 and Later FLHR/C Models
  1. Remove main fuse.
  2. See Figure 2. Disconnect signal connectors.
  3. Remove pin 6-way housing with right turn signal wires. Remove pin 4-way housing for left turn signal wires.
1Pin 6-way housing with right turn signals wires
2Pin 4-way housing for left turn signal wires
Figure 2. Headlamp Nacelle Connectors (FLHR/C only)
Remove Auxiliary Mounting Bracket (FLHR/C)
1.
See Figure 3. Remove and discard acorn nuts and washers from three mounting positions on auxiliary mounting bracket.
1Acorn nut (4)
2Washer (4)
3Auxiliary mounting bracket
Figure 3. Auxiliary Mounting Bracket (FLHR/C)
2.
See Figure 4. Remove acorn nut and washer to release clutch cable from P-clamp fastened to upper fork bracket (left side). Discard acorn nut and washer, but save P-clamp and clutch cable for later use.
3.
Remove stud from upper fork bracket (left side) but leave studs in other three mounting positions in place.
4.
See Figure 5. Remove auxiliary mounting bracket from motorcycle. The bracket includes auxiliary lamps and front turn signals.
1Acorn nut and washer
2P-clamp
3Clutch cable
Figure 4. Clutch Cable Routing (FLHR/C)
1Auxiliary lamp (2)
2Front turn signal (2)
3Auxiliary mounting bracket
Figure 5. Auxiliary Lamps and Front Turn Signals (FLHR/C)
Remove Turn Signals and Bracket (FLHRS)
1.
Carefully cut cable strap to release turn signal lamp conduit from lower handlebar clamp. Draw free end of conduit out of headlamp nacelle.
2.
Remove two cable clips anchored in holes at bottom of handlebar. Free turn signal lamp conduit from cable clips.
3.
See Figure 6. Remove acorn nut (1), lockwasher (2), and turn signal lamp bracket (3) from stem of mirror.
4.
Remove turn signal lamp assembly (4).
5.
Install acorn nut and lockwasher to stem of mirror.
1Acorn nut
2Washer
3Bracket
4Turn signal lamp assembly
Figure 6. Front Turn Signal Lamp (FLHRS)
6.
See Figure 6. Using a T40 Torx® drive head, remove screws and washers from three mounting positions on fork bracket. Discard washers but save screws for later use.
7.
Using a T40 Torx® drive head, remove screw and washer to release clutch cable from P-clamp fastened to upper fork bracket (left side). Discard screw and washer but save P-clamp and clutch cable for later use.
1Torx screw and washer
2P-clamp
3Clutch cable
Figure 7. Clutch Cable Routing (FLHRS)
INSTALLATION
Assemble Custom Front Turn Signal (FLHR/C/S)
1.
See Figure 8. Insert wire terminals (1) through the triangular opening (2) in turn signal bracket (3) from kit.
2.
Fit front turn signal lamp (4) onto bracket.
3.
Apply a small amount of Loctite 243 (blue) 99642-97 to the screw.
4.
Secure front turn signal lamp on bracket with screw (5).
5.
Tighten screw to 20–27 N·m (15–20 ft-lbs).
6.
Place bottom plate (6) on turn signal bracket so slot in bottom plate is facing rearward.
7.
See Figure 9. Route turn signal wiring through slot in bottom plate.
1Wire terminals
2Triangular opening in turn signal bracket
3Turn signal bracket
4Turn signal lamp
5Screw
6Bottom plate
Figure 8. Custom Front Turn Signal and Bracket (FLHR/C/S)
Figure 9. Feed Wiring through Slot in Bottom Plate
Install Custom Front Turn Signal and Bracket (FLHR/C)
1.
See Figure 10. Install turn signal and bracket assembly (1) using existing studs (2), and washers (3) and acorn nuts (5) from kit in three mounting locations.
NOTE
FLHR/C: Bracket assembly will be assembled outboard of the original equipment windshield mounting bushings.
Make sure that the turn signal wire is not pinched between the turn signal bracket and motorcycle.
2.
Apply a small amount of Loctite 243 (blue) 99642-97 to stud (6) from kit.
1Turn signal and bracket
2Existing stud (3)
3Washer (3)
4Larger spacer
5Acorn nut (4)
6Stud
Figure 10. Custom Front Turn Signal Mounting (FLHR/C)
3.
Turn stud 8-10 turns maximum to make sure there is enough thread for acorn nut.
4.
See Figure 11. Capture clutch cable (1) in P-clamp (2) and faster to upper fork bracket (left side) with stud (3) (item 6, Figure 10 ), large spacer (4), and acorn nut (5) from kit. On left side of steering head, run cable downward between engine guard and front of left frame downtube.
5.
Tighten stud and acorn nut to 20–27 N·m (15–20 ft-lbs).
1Clutch cable
2P-clamp
3Stud
4Large spacer
5Acorn nut
Figure 11. Clutch Cable Routing (FLHR/C)
Install Custom Front Turn Signal and Bracket (FLHRS)
1.
See Figure 12. Install turn signal and bracket assembly (1) using existing Torx screws (2) and washers (3) from kit in three mounting locations.
NOTE
Be careful so the turn signal wire is not pinched between turn signal bracket and motorcycle.
2.
Apply a small amount of Loctite 243 (blue) 99642-97 to screw (5) from kit.
1Turn signal and bracket
2Existing Torx screw (3)
3Washer (3)
4Large spacer
5Torx screw
Figure 12. Custom Front Turn Signal Mounting (FLHRS)
3.
See Figure 13. Capture clutch cable (1) in P-clamp (2) and fasten to upper fork bracket (left side) with large spacer (3), and Torx screw (4) from kit. On left side of steering head, run cable downward between engine guard and front of left frame downtube.
4.
Using a T40 Torx® drive head, tighten screw to20–27 N·m (15–20 ft-lbs).
1Clutch cable
2P-clamp
3Large spacer
4Torx screw
Figure 13. Clutch Cable Routing (FLHRS)
Wiring Connections and Final Assembly (FLHR/C/S)
2013 and earlier models:
1.
See Figure 14. Route turn signal wiring toward harness connector inside headlamp nacelle.
1Turn signal and bracket
2Turn signal wiring
3Clutch cable
Figure 14. Turn Signal Wire Routing
2.
Reuse socket housing for front turn signal lamps previously removed and insert terminal ends (see Table 1 ) into pin housing.
3.
FLHR/C: Reuse socket housing for auxiliary lamps previously removed and insert terminal ends into pin housing to protect open wire connection.
4.
See Figure 15. Secure turn signal wires around front fork and inside nacelle, and make sure the wire is above the fork stop.
5.
Swing fork assembly from stop to stop to make sure the turn signal wires do not get pinched between fork and frame.
NOTE
Make sure turn signal wires are not too tight around nacelle so it does not rub against the sharp edge in backside of nacelle. A gap of 3/8 in. is recommended to be adequate clearance between the wires and the edge surface.
6.
Use remaining cable straps to secure turn signal wires to main harness in headlamp nacelle.
Table 1. MY 13 and Earlier: Wire Color and Cavity Locations
Left and Right Turn Signals
Right Turn Signal
Cavity
1
2
3
6-Place Connector
Blk
Brn
Blue
Left Turn Signal
Cavity
4
5
6
6-Place Connector
Blue
Vio
Blk
1Slack in turn signal wire
2Tie strap
3Gap between turn signal wire and bottom edge of nacelle (allow for 3/8 in.)
Figure 15. Secure Front Turn Signal Wire
2014 and Later FLHR/C MODELS:
NOTE
Not all cavities are used. See Table 2 for wire location.
1.
Route wires toward steering head.
2.
Collect AMP 4-way for left turn signal and 6-way housings with right turn signal.
3.
See Table 2. Install right turn signal wires into 6-way connectors. Install left turn signal wires into 4-way connectors.
4.
Connect and secure wires. Similar to Figure 15.
5.
Install headlamp assembly. Refer to HEADLAMP ASSEMBLY, INSTALLATION in Service Manual.
6.
Be careful so the turn signal wire is not pinched between turn signal bracket and motorcycle. Swing fork assembly from stop to stop to be sure.
7.
Install main fuse. Refer to SYSTEM FUSES, MAIN FUSE in service manual.
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)
8.
Test all lights and switches.
Table 2. Wire Locations - 2014 and Later FLHR/C Models
Cavity
Color (Function)
1
Black (Ground)
2
Brown or Violet (Front R/L Turn Signal)
3
Blue (Run)
4
No longer used (Aux Lamp)
5
Not used on 6-way connector
6
Not used on 6-way connector
SERVICE PARTS
Figure 16. Service Parts: Custom Touring Bullet Front Turn Signal Kit
Table 3. Service Parts: Custom Touring Bullet Front Turn Signal Kit
Item
Description (Quantity)
Part Number
1
Bracket, turn signal, L.H.
69278-06
Bracket, turn signal, R.H.
69279-06
2
Turn signal, front (domestic) (2)
69371-06
Turn signal, front (HDI) (2)
69372-06
3
Screw, hex cap, 5/16-18 x 3/4 in. (2)
3987
4
Plate, bottom (2)
69689-06
5
Washer (3)
34075-89
6
Nut, acorn (4)
7527
7
Spacer
59060-92
8
Stud (FLHR/C)
3078
9
Screw, button head, Torx (FLHRS)
4187
10
Strap, tie (6)
10065
11
Housing, socket, 6-place
73156-96BK
12
Housing, socket, 4-place
73154-96BK
A
Stud (FLHR/C)
Stock Part
B
Screw, button head, Torx (FLHRS)
Stock Part