| 1. | Remove seat. | |
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
| 2. | Disconnect negative battery cable. | |
| 3. | See Figure 3. Remove and save the fender support front bolt (1). NOTE Make sure you use the coarse (3/8-16) threaded nut in the next step. Attempting to install the fine (3/8-24) threaded nut on bolt (1) will damage threads on both nut and bolt. | |
| 4. | Place the countersunk side of the front docking point (2) facing fender support. Insert bolt (1) from kit through docking point (2) and into fender. Install washer (8) and locknut (11) from inside of fender. Tighten bolt to 37 N·m (27 ft-lbs). |
| 1. | See Figure 1. Remove lens (1) from rear turn signal housing (2). Remove bulb (3) from directional housing socket. | |||||||||||||
| 2. | Trace turn signal wire routing along underside of rear fender. Remove cable strap located on topside of rear fender near the rubber grommet. Bend internal fender clips outward. Do not remove wires from the clips. Gently pull excess wire rearward along underside of fender and into turn signal housing to allow for additional length of wire within turn signal housing. Bend fender clips back into place. NOTE In the next step, if vehicle is equipped with Bullet Style (small diameter) Turn Signals, the splice must be made under the fender. Cut and splice wiring at a suitable location under fender versus inside turn signal housing. | |||||||||||||
| 3. | Cut wires within turn signal housing about 3 inches away from point where wires connect to the bottom of the bulb socket. From underside of fender, withdraw end of wires within turn signal housing support (4) into the inner fender area. | |||||||||||||
| 4. | Remove and discard 5/16 inch bolt and lockwasher (6) (from inside of fender) securing rear turn signal and support. | |||||||||||||
| 5. | Remove and discard the vinyl conduit on the turn signal wires back to the fender support. Be careful not to cut the turn signal wires. | |||||||||||||
| 6. | Remove and discard fender support rear bolt (threaded into license plate bracket). | |||||||||||||
| 7. | Route turn signal wires through hole in which rear bolt was just removed (through license plate bracket and out fender support). |
Figure 1. Install Turn Signal | ||||||||||||
| 8. | See Figure 3. Obtain the new signal mount and rear docking point. Slide the docking point over the long end of the turn signal mount so that countersunk side faces the fender support. | |||||||||||||
| 9. | Route wiring through signal mount. Using the flats on signal mount, thread the mount (with docking point installed) into the last hole (and license plate bracket) and tighten to 30 N·m (22 ft-lbs). | |||||||||||||
| 10. | Thread the jamnut (8), oriented as shown, onto end of signal mount until it bottoms on the threads. | |||||||||||||
| 11. | Continue to route wiring from signal mount into turn signal mounting hole. | |||||||||||||
| 12. | Install rubber plug (6) from kit into signal housing hole vacated by original wire routing. | |||||||||||||
| 13. | Thread the signal lamp housing on the mount until it bottoms on the jamnut. Slowly back it up until the lamp is correctly aligned, then while holding housing, tighten jamnut against housing to 24 N·m (18 ft-lbs). | |||||||||||||
| 14. | Obtain front fender support bolt removed in Step 1 and thin locknut (7) from kit. Install into second hole from end of fender support and tighten to 30 N·m (22 ft-lbs). | |||||||||||||
| 15. | Install chrome hole plug (5) in fender support hole previously used for turn signal wires. NOTE In order to achieve a snug fit, the tines of the hole plug may have to be spread apart. To spread the tines, hold the cap end of the plug firmly and using a pliers, bend each of the tines outward slightly. Repeat this as necessary to achieve a snug fit. |
| 1. | Strip a 3/8 inch section of insulation from both ends of each turn signal wire now inside the turn signal housing. | |||||||
| 2. | See Figure 2. Insert turn signal wires prepared in step 1 into opposite ends of a butt splice connector. Connect black to black and violet/brown to violet/brown. | |||||||
| 3. | Match the color of the butt splice connector with the color of the crimp cavity of the crimping tool. Using a H-D 38125-8 crimping tool, crimp wires into the connector. | |||||||
| 4. | Using the UltraTorch UT-100 (Part Number 39969), Robinair Heat Gun (Part Number 25070) with Heatshrink Attachment (Part Number 41183), or other suitable radiant heating device. Heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the melting sealant exudes out of both ends of the connector. |
Figure 2. Installing Sealed Butt Connectors | ||||||
| 5. | Install bulb into turn signal housing socket. Install lens to turn signal housing. | |||||||
| 6. | Repeat all installation procedures on the other side of motorcycle. | |||||||
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) | ||||||||
| 7. | Connect battery cables, positive cable first. | |||||||
| 8. | Check turn signals for proper operation. | |||||||
| 9. | Install seat. |
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Bolt, button head 3/8-16 x 2-1/4 | 4154 |
2 | Docking points, front (2) | 53683-96 |
3 | Docking points, rear (2) | 53684-96A |
4 | Turn signal mount (per respective kits) | 53880-01A |
5 | Plug, chrome | 56239-93 |
6 | Turn signal housing plug (2) | Not Sold Separately |
Items mentioned in text, but not included in kit: | ||
A | Nut, front fender support | |
B | Bolt, button head 3/8-16 x 2-1/4 | |