ROAD TECH ELECTRONIC COMPASS KIT
J025082005-09-26
GENERAL
Kit Number
74445-05, 74446-05, 74498-05
Models
These Road Tech™ Compass kits are designed to fit the following motorcycles:
- 1997 and later FLHR/I (Road King®)
- 1998 and later FLHRCI (Road King® Classic)
- 1999 and later FXST/I (Softail® Standard)
- 1998 and later FXSTB/I (Night Train®)
- 1996-1999 FXSTC/I (Softail® Custom)
- 2000 and later FXSTD/I (Softail® Deuce®)
- 1996 and later FXSTS/I (Springer® Softail®)
- 1996 and later FLSTC/I (Heritage Softail® Classic)
- 1996 and later FLSTF/I (Fat Boy®)
- 1997-2003 FLSTS/I (Heritage Springer®)
- 1996 and later FXDWG/I (Dyna Wide Glide®)
- 1999 and later XL883C (Sportster® 883 Custom)
- 1986 and later XL 1200C (Sportster® 1200 Custom)
Table 1. Models
Kits | Models |
|---|---|
Kit 74445-05 | has a black face with white lettering |
Kit 74446-05 | has a silver face with black lettering |
Kit 74498-05 | has a polymetal face (spun aluminum-look finish with black ring) and white lettering |
Additional Parts Required
In order to properly install this compass kit, a 2-Inch Gauge Housing Kit and an 2-Inch Gauge Bracket Kit for your model motorcycle are required. The correct housing and bracket kits can be purchased separately from any Harley-Davidson Dealer.
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
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
For 2003 and earlier XL or FXDWG models, and ALL Softails:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware.
For 2004 and later FXDWG models:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the Service Manual and follow the instructions given to remove the maxi-fuse.
For 2004 and later Sportster models:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware.
ALL Models
WARNINGWhen servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
| 1. | Loosen the fuel tank as necessary to provide access to the headlamp connector [38]. Refer to FUEL TANK-REMOVAL in the Service Manual. | |
| 2. | See Figure 6. Obtain the compass bracket from the Compass Bracket Kit and the isolation gasket (3) from the Electronic Compass Kit (sold separately). Install the gasket into the bracket with the grommet portion in the six o'clock (straight down) position. NOTE DO NOT install the connector housings to the compass leads until the wiring has been routed to the connection point. | |
| 3. | Obtain the compass gauge (1) from the Electronic Compass Kit. Feed the compass harness through the grommet portion of the isolation gasket. | |
| 4. | Slide the compass gauge into the bracket from the front side, making sure to align the gauge with the "U"- shaped indicator window in the twelve o'clock (straight up) position. | |
| 5. | Obtain the compass cup (C) and two button-head screws (B) from the Gauge Housing Kit, and the rubber pad (8) from the Electronic Compass Kit. Peel the paper backing from the rubber pad, and attach it to the inside of the compass cup, between the mounting holes in the back of the cup. Insert the screws, from the outside, through the holes. | |
| 6. | Slide the cup onto the compass gauge until the cutout at the bottom of the cup fits around the grommet portion of the gasket, and the cup edge seats in the gasket slot. | |
| 7. | Secure the cup to the gauge with the two screws, and tighten to 2.2–3.4 N·m (20–30 in-lbs). | |
| 8. | Obtain the yellow "pass-through" lead (10), and the four cavity pin (6) and socket (7) housings from the Electronic Compass Kit. | |
| 9. | See AMP MULTILOCK ELECTRICAL CONNECTORS in the Service Manual for terminal installation instructions. Insert the terminals on the compass harness into the proper housing cavities as follows: |
- Orange/ white wire to cavity 1 of the socket housing. Cavity 1 of the pin housing remains unused.
- White wires to cavity 2 of each housing.
- Connect the yellow lead (H) from the Compass Kit to cavity 3 of each housing.
- Black wires to cavity 4 of each housing.
| 10. | Disconnect the headlamp connector halves [38A] and [38B], located toward the front of the fuel tank. Connect the compass pin and socket housings to the headlamp connectors. | |
| WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) | ||
| 11. | Tighten the fuel tank. Refer to FUEL TANK-INSTALLATION in the Service Manual. | |
| 12. | Install the compass and bracket assembly to the motorcycle according to the instructions in the Bracket Kit. | |
| 13. | Remove and discard the static label from the gauge face, then set the correct zone and calibrate the compass per the instructions that follow. |
INSTALLATION
1997 and later FLHR/I and 1998 and later FLHRCI
For 2003 and earlier models:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative battery cable. Retain all seat mounting hardware.
For 2004 and later models:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the Service Manual and follow the instructions given to remove the maxi-fuse.
For 2004 and later models:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the Service Manual and follow the instructions given to remove the maxi-fuse.
For ALL models:
| 14. | See Figure 6. Obtain the compass bracket from the Compass Bracket Kit and the isolation gasket (3) from the Electronic Compass Kit. Install the gasket into the bracket with the grommet portion in the six o'clock (straight down) position. NOTE DO NOT install the connector housings to the compass leads until the wiring has been routed to the connection point. | |
| 15. | Obtain the compass gauge (1) from the Electronic Compass Kit. Feed the compass harness through the grommet portion of the isolation gasket. | |
| 16. | Slide the compass gauge into the bracket from the front side, making sure to align the gauge with the "U"- shaped indicator window in the twelve o'clock (straight up) position. | |
| 17. | Obtain the compass cup (C) and two button-head screws (B) from the Gauge Housing Kit, and the rubber pad (8) from the Electronic Compass Kit. Peel the paper backing from the rubber pad, and attach it to the inside of the compass cup, between the mounting holes in the back of the cup. Insert the screws, from the outside, through the holes. | |
| 18. | Slide the cup onto the compass gauge until the cutout at the bottom of the cup fits around the grommet portion of the gasket, and the edge of the cup seats in the gasket slot | |
| 19. | Secure the cup to the gauge with the two screws, and tighten to 2.2–3.4 N·m (20–30 in-lbs). | |
| 20. | Obtain the two-cavity pin (4) and socket (7) housings from the Electronic Compass Kit. | |
| 21. | See AMP MULTILOCK ELECTRICAL CONNECTORS in the Service Manual for terminal installation instructions. Insert the terminals on the compass harness into the proper housing cavities as follows: |
- Orange/ white wires to cavity 1 of each housing.
- Black wires to cavity 2 of each housing.
- Cut off and discard the splice and terminal ends of the white wire (A).
- Cut the white (high beam) wire going to the headlight connector [38B] in the area inside the nacelle. Do not cut into the insulation of the wires inside the conduit. Damage to the wiring can lead to loss of lighting while riding, which could result in death or serious injury.
- Carefully slice a small opening in the conduit covering the compass harness inside the nacelle. Bring the white wire lead out through the cut opening in the conduit, and cut to length to easily reach the white headlight wire.
- Carefully slice a small opening in the conduit covering the compass harness inside the nacelle. Bring the white wire lead out through the cut opening in the conduit, and cut to length to easily reach the white headlight wire.
- See SEALED BUTT-SPLICE CONNECTORS in the Service Manual to splice the white compass wire to the white headlight lead inside the nacelle, using a #16-14 gauge sealed butt-splice connector (H-D part number 70586-93, not supplied).
NOTE
Do not cut into the insulation of the wires inside the conduit. Damage to the wiring can lead to loss of lighting while riding.
WARNINGBe sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
- Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/ explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
- FLHR/I models: Disconnect the fender tip lamp connector halves [32A] and [32B] inside the nacelle. Connect the compass pin and socket housings to the fender tip lamp connectors. FLHRCI models: Locate the unused fender tip lamp pin housing connector [32A] inside the nacelle. Connect the compass socket housing to connector [32A]. The compass pin housing can remain unconnected inside the nacelle.
- Install the compass and bracket assembly to the motorcycle according to the instructions in the Bracket Kit.
- Remove and discard the static label from the gauge face, then set the correct zone and calibrate the compass per the instructions that follow.
SETTING THE ZONE AND CALIBRATING THE COMPASS
Figure 1. Zones
NOTE
Upon initial power up of the compass after installation, the gauge will continually spin until zone selection and calibration procedures have been successfully completed.
The compass must be adjusted to operate in the zone in which it will be used. Therefore, the correct zone must be programmed into the compass. See Figure 1a for locations within the "lower 48" United States. See Figure 2 for Canada and Alaska. Hawaii is in zone seven. Travel across several zones should not significantly affect compass accuracy.
See Figure 1b. The compass gauge display is used to indicate the zone currently selected or stored in memory. "N" indicates zone one is selected, "NNE" indicates zone two, and so on.
The compass must also be calibrated after it has been installed in its permanent location on the vehicle. This allows it to compensate for the influence of the motorcycle structure in its determination of the correct heading.
| 1 | NOTE: For Hawaii calibrate to Zone 7 (SE) |
Figure 2. Zone Chart for Alaska and Canada (With Compass Gauge Equivalents)
The initial zone-setting and calibration of the compass can be accomplished by following the flow chart in Figure 4.
- See Figure 3. The calibration procedure involves positioning the motorcycle in sixteen (16) directions evenly distributed around a 360 degree circle on level ground free of large buildings, power lines, etc.
- The calibration can be started with the vehicle pointed in any direction.
- A hi/lo sequence of the headlamp switch will set the zone and initiate calibration.
- Sixteen data points are needed for calibration.
Figure 3. Motorcycle Positioning For Calibration
Figure 4. First Time Zone Selection and Calibration Procedure
Please read through and understand the entire flow chart before starting the calibration procedure.
Calibration information is stored in non-volatile memory, and re-calibration will not be needed if power to the unit is disconnected. However, when travel to another zone introduces noticeable inaccuracy the new zone should be stored in memory in order to maintain compass accuracy.
Follow the flow chart in Figure 5 to store a new zone without re-calibrating.
Figure 5. To Store a New Zone Without Re-calibrating
Use
It is not necessary for the headlamp switch to be "ON" for the compass to be operational.
Metallic objects not present during calibration can alter the compass readings. Metal items normally mounted or carried in the compass area (such as in a windshield bag) should be present during calibration and kept there afterward. When adding metallic items near the compass, re-calibrate with the item in place.
The calibration and zone-storing procedure flow charts have been repeated on the last sheet of these instructions. The lower section of that sheet can be cut off, laminated and kept with you as a handy reference when traveling, if desired.
Table 2. Troubleshooting
Problem: | Possible Cause: | Solution |
|---|---|---|
Spinning compass face: | Initial setup not successfully completed? | Perform initial zone-setting and calibration procedures. |
Won't enter calibration mode: | Faulty headlamp switch? | Check switch and replace if necessary. |
Cannot enter zone selection mode: | Loose headlamp switch connection? Toggling headlamp switch too fast or slow? | Verify correct wiring, especially proper ground. Toggle the switch within 10 seconds to advance one zone. |
Cannot change zone: | Toggling headlamp switch too slow? | Toggle the switch within 10 seconds to advance one zone. |
Calibration won't "take": | Calibration procedure start direction (see Note 1) | Re-orient bike to check for proper compass operation. |
Metallic object in compass area? | Remove object(s) and repeat calibration procedure. | |
Improperly performed calibration? | Repeat calibration procedure. | |
Compass is inaccurate: | Wrong zone selected? | Perform compass new-zone storage procedure. |
Motorcycle not straight upright or front wheel not pointed straight ahead during collection of one or more data points? | Repeat calibration procedure. | |
Sixteen data points collected were not evenly distributed around the 360 degree circle? | Repeat calibration procedure (see Note 2). | |
Always happens in same or similar situation? | May be situation-dependent. Recognize and compensate. | |
Sudden onset, but constant? | Metallic object newly stored or mounted near compass. | |
Sudden onset, but erratic? | Check for loose mounting or wire connection. |
NOTE
1. The motorcycle can be aimed in any direction at the start of the calibration procedure. If the vehicle happened to be aimed due North at the beginning, the final data point acquisition display (N-NW) will be identical to the actual orientation of the bike, and the display will not change. To determine if this is the case, aim the motorcycle in a different direction. If the display changes to display the correct new direction, no further action is necessary.
2. While the sixteen data points do not need to be exactly 22-1/2 degrees apart, they should be as close to that angle as possible. As a quick reference, after collecting four data points spaced in reasonably equal increments, the vehicle should have rotated very close to 90 degrees, or one-fourth of a complete circle.
SERVICE PARTS
Figure 6. Service Parts: Road Tech Electronic Compas Kit
Table 3. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Compass gauge (includes bulb and pass-thru lead) | |
Black/white face | Not Sold Separately | |
Silver/black face | Not Sold Separately | |
Polymetal face | Not Sold Separately | |
2 | Bulb, compass lamp | |
Amber (for black or silver gauge) | 67589-02 | |
Red (for polymetal gauge) | 74646-05 | |
3 | Gasket, compass isolation | 67927-05 |
4 | Pin housing, 2-cavity | 73102-96BK |
5 | Socket housing, 2-cavity | 73152-96BK |
6 | Pin housing, 4-cavity | 73104-96BK |
7 | Socket housing, 4-cavity | 73154-96BK |
8 | Rubber pad | 69295-05 |
9 | Cable strap (5) | 10006 |
10 | Connector, pre-insulated, sealed, butt-splice, #16-14 gauge (blue) | 70586-93 |
Items mentioned in text, but not included in kit: | ||
A | White compass lead | |
B | Button head screwes (2) | |
C | Compass cup | |
Figure 7. To Store a New Zone Without Re-calibrating
Figure 8. Compas Re-calibration Procedure
This page may be cut off, laminated and kept as a reference.