PREMIUM AIR HORN INSTALLATION KIT
J037642008-08-20
GENERAL
Kit Number
69400-05A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
A Premium Air Horn (69423-05) is needed for proper installation of this kit. This item is available from a 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.
Electrical Overload
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
WARNINGWhen installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
The Premium Air Horn requires up to 18 Amps additional current from the electrical system when sounding the horn.
REMOVAL
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNINGDisconnect 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)
- Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Save all seat mounting hardware for installation.
- See Figure 1. Remove the acorn nut (1) and flat washer (2) to free the horn assembly from the rubber mount (3) stud. Remove the rubber mount from the weld nut on the engine strap, and discard the mount.
- Remove the elbow terminals (4) from the two spade contacts on the horn (9), and release the main harness conduit (5) from the J-clamp (6).
- Cut the elbow terminal from ONLY the yellow/ black wire on the main harness conduit.
- Remove the 10 mm flange nut (7) from the circular recess at the back of the horn bracket (8). Remove the horn from the chrome horn cover (10).
NOTE
DO NOT cut the elbow terminal from the black wire.
| 1 | Acorn nut |
| 2 | Flat washer |
| 3 | Rubber horn mount |
| 4 | Elbow terminals (2) |
| 5 | Main harness |
| 6 | J-clamp |
| 7 | Flange nut |
| 8 | Horn bracket |
| 9 | Horn |
| 10 | Chrome horn cover |
| 11 | Speed nut |
| 12 | Screw, serrated flange |
Figure 1. Original Equipment Horn Removal
INSTALLATION
New Horn Installation
| 1. | See Figure 4. Assemble the horn mounting bracket (1) to the weld nut on the engine strap (C), with the bent tab toward the vehicle, using the screw (2) and washer (3). Do not fully tighten at this time. | |
| 2. | Insert the threaded stud on the isolator (5), from the outside, into the large hole in the horn mounting bracket. Fit the three pins on the isolator into the small holes in the bracket, and fasten the isolator to the bracket with the lock nut (4). Tighten to 9–11.3 N·m (80–100 in-lbs). NOTE Rotate the bracket so the horn is aimed forward and down at a 45 degree angle for best sound dispersion. | |
| 3. | Rotate the horn mounting bracket clockwise, to the orientation shown in Figure 4. Tighten the chrome hex screw to 9–11.3 N·m (80–100 in-lbs). | |
| 4. | Obtain the Premium Air Horn (item A, purchased separately), the socket head screw (6) and small chrome flat washer (7) from this kit. Hook the mounting block (D) on the back of the horn over the T-stud (E) on the isolator. Align the hole on the top of the mounting block with the threaded hole in the T-stud. | |
| 5. | Fasten the horn to the stud with the screw and washer. Tighten to 11–14 N·m (100–120 in-lbs). |
New Horn Wiring - 1997 through 2007 Models
| 1. | See Figure 2. Feed the long branch of the horn wiring harness (from the kit) into the space (1) in front of the vehicle battery and under the frame crossmember (2). a. Bring the long harness branch out through the top opening in the crossmember, and forward along existing harnesses on the left side of the frame (3). b. Bring the short branch with the ring terminal and black wire sleeve under the frame crossmember (2), and attach to the left side ground stud (4). c. Bring the branch with the ring terminal and red wire sleeve over to the area of the battery positive (+) terminal and tuck the fuse holder into the available space in front of the battery. d. See Figure 4. Position the relay (F) on the harness with the electrical connector at the bottom. Use a cable strap (10) to fasten the relay to the frame crossmember in front of the battery. | 
Figure 2. Horn Harness Routing, FL Touring Models (2005 Shown) | ||||||||||
| 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) | ||||||||||||
| 2. | Loosen the fuel tank. Refer to the appropriate section (Carbureted or EFI Engine) of the service manual. | |||||||||||
| 3. | Continue the long branch of the horn harness forward to a point directly above the new horn. Fasten the horn harness to the existing harnesses rearward of the horn with cable straps from the kit as needed. | |||||||||||
| 4. | Continue routing the horn harness branch down to the horn. Plug the elbow terminal on the yellow wire into one of the terminals on the underside of the horn. | |||||||||||
| 5. | Plug the elbow terminal on the black wire of the main harness conduit into the remaining horn terminal. | |||||||||||
| 6. | Refer to the service manual. Connect the yellow/ black wire on the main harness conduit to the sealed splice connector on the yellow/ black wire on the horn harness. | |||||||||||
| 7. | Push the air intake tube (B) connector into the opening near the bottom of the horn until the tab retainer clicks into place. NOTE Position the air intake tube so it will not get pinched by the seat or fuel tank after installation, contact hot engine or exhaust components, or interfere with the operation of the motorcycle. Do not pinch the tube when tightening the cable straps. | |||||||||||
| 8. | Route the tube up to the area under the seat. Tie the tube to the motorcycle with cable straps as needed. Do not pinch the tube by over-tightening the straps. Cut off any excess tube or strap length. | |||||||||||
| 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) | ||||||||||||
| 9. | Tighten the fuel tank. Refer to FUEL TANK-INSTALLATION (AFTER PARTIAL REMOVAL) in the appropriate section (Carbureted or EFI Engine) of the service manual. |
New Horn Wiring - 2008 Models
| 1. | Remove the top electrical caddy following the instructions in the service manual. | |||||||||
| 2. | See Figure 3. Route the horn wiring harness (from the kit) under the main harness and up the wiring trough (4). a. Bring the branch with the ring terminal and black wire sleeve and attach to the front ground stud (1). b. Bring the branch with the ring terminal and red wire sleeve over to the area of the battery positive (+) terminal (2), and tuck the fuse holder into the available space in front of the battery. Do not connect to the positive terminal at this time. c. Position the relay (3) on left side of battery. Use a short cable strap to attach the relay to the left side electrical caddy. | 
Figure 3. Horn Wiring Routing - 2008 Models | ||||||||
| 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) | ||||||||||
| 3. | Remove the fuel tank. Refer to FUEL TANK-REMOVAL in the appropriate section (Carbureted or EFI Engine) of the service manual. | |||||||||
| 4. | Continue the long branch of the horn harness forward to a point directly above the new horn. Fasten the horn harness to the existing harnesses rearward of the horn with long cable straps from the kit as needed. | |||||||||
| 5. | Continue the horn harness branch down to the horn. Plug the elbow terminal on the yellow wire into one of the terminals on the underside of the horn. | |||||||||
| 6. | Plug the elbow terminal on the black wire of the main harness conduit into the remaining horn terminal. | |||||||||
| 7. | Refer to the service manual. Connect the yellow/ black wire on the main harness conduit to the sealed splice connector on the yellow/ black wire on the horn harness. | |||||||||
| 8. | Push the air intake tube (B) connector into the opening near the bottom of the horn until the tab retainer clicks into place. NOTE Position the air intake tube so it will not get pinched by the seat or fuel tank after installation, contact hot engine or exhaust components, or interfere with the operation of the motorcycle. Do not pinch the tube when tightening cable straps. | |||||||||
| 9. | Route the tube up to the area under the seat. Fasten the tube to the motorcycle with short cable straps as needed. Do not pinch the tube by over-tightening the straps. Cut off any excess tube or strap length. | |||||||||
| 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) | ||||||||||
| 10. | Install the fuel tank. Refer to FUEL TANK-INSTALLATION in the appropriate section (Carbureted or EFI Engine) of the service manual. |
Final Assembly - All Models
NOTE
To prevent possible damage to the electrical system, verify that the ignition/light key switch is in the OFF position before connecting the battery cables.
| 1. | Verify that the ignition/light key switch is in the OFF position. | |
| 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) NOTICE Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a) | ||
| 2. | Refer to the service manual and follow the instructions given to connect the positive (red) battery cable and install the horn harness ring terminal with the red wire sleeve to the positive (+) battery terminal. | |
| 3. | Follow the instructions to connect the negative (-) battery cable to the negative (-) battery terminal. | |
| 4. | If removed, install the top electrical caddy per the instructions in the service manual. | |
| 5. | Refer to the service manual and follow the instructions to install the 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) | ||
| 6. | Test the horn for proper operation. |
SERVICE PARTS
Figure 4. Service Parts: Horn Installation Kit
Table 1. Service Parts: Horn Installation Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Bracket, horn mounting | 69472-05A |
2 | Screw, mounting bracket (5/16-18) | 94193-91T |
3 | Flat washer, mounting bracket | 6781 |
4 | Hex lock nut, with nylon insert (5/16-18) | 7739 |
5 | Isolator | 69471-05 |
6 | Screw, isolator (1/4-20) | 3063 |
7 | Flat washer, isolator | 6220W |
8 | Wire harness, horn (includes item 9) | 69416-05 |
9 |
| 72315-05 |
10 | Cable strap, short (10) | 10006 |
11 | Cable strap, long (4) (not shown) | 10039 |
Items mentioned in text, but not included in kit: | ||
A | Horn (Part Number 69423-05, includes item B) | |
B |
| |
C | Engine strap | |
Items mentioned in text: | ||
D | Mounting block on horn | |
E | T-stud on isolator | |
F | Relay on horn harness | |