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SPRINGER AUXILIARY LAMP KIT
J034972007-10-24
GENERAL
Kit Number
69286-05A
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase and installation of auxiliary/fog lamps are required for proper installation of this kit on your model motorcycle. Please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only). HDI (international) motorcycles should only use approved fog lamps.
Separate purchase of LOCTITE® 273 Threadlocker and Sealant - Blue is required for proper installation of this kit. LOCTITE can be purchased from any Harley-Davidson Dealer.
WARNING
Rider 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.
Special Tools
Separate purchase of a crimping tool (Kent-Moore part number HD-38125-8 or equivalent) is required to install this kit.
Kit Contents
See Figure 17 and Table 1.
WARNING
When 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)
REMOVAL
Prepare the Motorcycle for Service
1. For EFI models: Follow the instructions in the appropriate Service Manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line.
2. Follow the instructions in the appropriate Service Manual to remove the seat.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
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)
3. Disconnect the negative (-) battery cable from the battery.
4. Follow the instructions in the appropriate Service Manual to remove the fuel tank.
Remove the Installed Hardware
1. See Figure 1. Remove the screw (4) and the brake line P-clamp (8) from the right side of the rigid fork. Save the P-clamp.
2. Remove the screw (7) and lockwasher (5) from the left side. Save the screw.
3. Remove the original acorn nut (1), flat washers (2) and bolt (3) holding the upper shock absorber. Save the washers and the acorn nut.
1Acorn nut
2Washer (2)
3Bolt, 3/8 in.
4Screw, 1/2 in. long
5Lockwasher
6Shock absorber
7Screw, 3/8 in. long
8Brake line P-clamp
Figure 1. Mounting Hardware
INSTALLATION
Mount the Bracket
1. Without horn kit: See Figure 17. Select the 3/8-16 x 2-1/2 in. cap screw (9) from this kit. With horn kit: Select the 3/8-16 x 3 in. zinc-plated screw from the horn kit.
2. Position the auxiliary lamp support bracket (7) with the wiring holes facing down and assemble the support bracket and accessories (as shown in Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 or Figure 7 ) to the upper shock mount sliding the selected screw from Step 1 through the components.
3. Install the flat washer and acorn nut previously removed from the shock absorber mount.
4. See Figure 17. Apply Loctite 243 (blue) to the threads and install the stock 5/16-24 x 1/2 in. socket head screw removed from the right side of the rigid fork, and a lockwasher (12) from the kit onto the left side to install the auxiliary lamp bracket long tab to the rigid fork.
5. Apply Loctite 243 (blue) to the threads of the screw (11) and install the screw and a lockwasher (12) through the brake line P-clamp and through the right side long auxiliary lamp support bracket long tab to the rigid fork.
6. Apply Loctite 243 (blue) to the threads of the upper shock mounting bolts and tighten to 61–67.8 N·m (45–50 ft-lbs).
7. Tighten the left and right rigid fork socket head screws securely.
1Horn bracket
2Windshield bracket
3Lamp support bracket
4Upper shock mount
Figure 2. 1992 and Earlier: Support, Windshield and Horn Configuration
1Horn bracket
2Windshield bracket
3Lamp support bracket
4Spacer
5Upper shock mount
Figure 3. 1993 and Later: Support, Windshield and Horn Configuration
1Horn bracket
20.09 in. (2.3 mm) spacer from horn kit
3Lamp support bracket
4Upper shock mount
Figure 4. 1992 and Earlier: Auxiliary Lamps and Horn Configuration
1Horn bracket
20.09 in. (2.3 mm) spacer from horn kit
3Lamp support bracket
4Spacer
5Upper shock mount
Figure 5. 1993 and Later: Auxiliary Lamps and Horn Configuration
1Windshield bracket
2Lamp support bracket
3Upper shock mount
Figure 6. 1992 and Earlier: Auxiliary Lamps and Windshield Configuration
1Windshield bracket
2Lamp support bracket
3Spacer
4Upper shock mount
Figure 7. 1993 and Later: Auxiliary Lamps and Windshield Configuration
Install and Wire the Auxiliary Lamp Housings
  1. See Figure 8. Install the U-clamp (1) around the support bracket (2) (with the open end facing the rear of the motorcycle) and install the lamp housing on the bracket.
  2. Hold the U-clamp and fit the bevel washers (3) to the curve of the support bracket.
  3. With the convex side of the Belleville washer (4) facing the lamp housing, thread the gray/black (GR/BK) wire (5) from the housing through the Belleville washer and then through the clamp and the two bevel washers.
  4. Fit the housing stud (6) through the Belleville washer, U-clamp and the bevel washers.
  5. Slip a washer (7) over the wire and housing stud and secure with the chrome acorn nut (8).
  6. See Figure 17. Install the inner nesting ring (21) on the lamp bulb (purchased separately).
  7. See Figure 9. Connect the black wire to the bulb spade terminal (2) next to the bulb indexing tab (1) on the bulb. Install the gray wire on the remaining spade terminal.
  8. See Figure 17. Install the bezel trim ring (18) with the screw (19) and nut (20).
  9. Use fish tape or wire to draw the lamp wire leads through the holes in the support bracket, along the inside of the bracket and through the single exit hole inside the left side long mounting tab.
  10. See Figure 17. Slide conduit (17) over each wire, until the end of the conduit is 2 in. (51 mm) inside the exit hole of the support bracket.
  11. Trim the opposite end of the conduit to expose a short length of lamp wire.
  12. Secure the wires to the inside of the right side long mounting tab on the support bracket with two short cable straps (14).
  13. Install hole plugs (8) in both ends of the support bracket.
1U-clamp
2Support bracket
3Bevel washer (2)
4Belleville washer
5Gray/black wire (GR/BK)
6Housing stud
7Washer
8Chrome acorn nut
Figure 8. Install Bracket
1Bulb index tab
2Spade terminal (2)
3Nesting ring index tab (2002 and later models)
Figure 9. Auxiliary Lamp Bulb Terminals
Route the Wire Harness
1. See Figure 10. Set the relay (1) of the wire harness in the opening of the seat pan.
WARNING
Improper wire routing can damage wires causing electrical failure, which could result in death or serious injury. (00503b)
2. Route the ground wire with ring terminal (2) to a ground stud.
3. Find the B+ connector [160B] (7) on the main wiring harness and route the white wire with connector (4) to the B+ connector.
4. Route the long center conduit along the frame backbone.
5. Route the lamp switch (3) and the lamp circuit conduit (6) to the left side of the motorcycle.
6. Route the white wire (4) to the headlamp.
7. Secure the long center harness to the main wiring harness with a cable strap.
Install Lamp Switch
1. See Figure 11. Remove the lower screw and washer from the left handlebar switch housing clamp (1).
2. See Figure 17. Mount the switch bracket (25) to the switch housing and tighten to 7–9 N·m (60–80 in-lbs).
3. Route the switch wires along the underside of the left handlebar push the switch (28) through the bracket opening and thread on the switch boot (24).
NOTE
See Figure 17. If the boot (24) becomes worn or damaged, or is lost, replace the boot to prevent moisture from entering the switch.
4. Replace the harness retainer (16) in the handlebar capturing the auxiliary lamp switch wire.
5. For International (HDI) models: Install the fog lamp (HDI) switch label (27) on the clutch control clamp.
1Relay
2Ground wire with ring terminal (BK)
3Lamp switch
4White wire (W)
5Fuse holder with 15 amp fuse
6Lamp circuit conduit
7Wire with B+ connector
Figure 10. Auxiliary Lamp Wire Harness
1Left handlebar switch housing clamp
Figure 11. Lamp Switch Mounting
Connect the Lamp Switch Circuit
  1. See Figure 12. Route the black wire (2) from the harness to the two lamp wires (4) and slide heat shrink tubing (1) over the black wire.
  2. Follow the instructions in the Sealed Splice procedure in the appropriate Service Manual and splice the black wire from the wire harness to the two lamp gray and black wires. Slide the conduit over the splice.
Connecting the Low Beam
NOTE
The auxiliary lamps can only be operated while the main headlamp is on low beam. This function meets the requirements of many state and local laws.
WARNING
Improper wire routing can damage wires causing electrical failure, which could result in death or serious injury. (00503b)
  1. Remove the headlamp trim ring and headlamp.
  2. Separate the connector from the bulb.
  3. See Figure 13. Route the unterminated white wire (1) from the auxiliary lamp harness through the grommet in the headlight housing.
    4. NOTE
    To route the wire through the grommet, push a hooked piece of wire through the grommet from the inside of the headlamp housing. Soap the white wire and pull it back through the grommet with the hooked wire.
  4. Cut the yellow low beam wire (2) 1.5 in. (38.1 mm) from the headlamp connector to leave sufficient length for a splice.
  5. Follow the instructions in the Sealed Splice procedure in the appropriate Service Manual and splice the cut end of the yellow wire from the connector to the white and yellow wires from the headlamp housing grommet.
    6. NOTE
    If the white wire from the harness does not fit through the grommet, the white wire may be spliced to the yellow wire outside the headlamp housing.
  6. Connect the connector to the spade connectors on the headlamp and install the headlamp and trim ring in the headlamp housing.
1Heat shrink tubing
2Black wire from kit harness
3Splice connector
4Lamp wires
5Conduit
Figure 12. Connect the Lamp Wires to the Kit Harness
1White wire from auxiliary lamp
2Yellow (low beam) wire
Figure 13. Splicing Headlight Wires
Connect the Auxiliary Lamps
  1. For 2003 and earlier models:
    1. Cut the connector from the white power lead on the lamp wire harness.
    2. See Figure 17. Crimp the ring terminal (23) to the lead.
    3. See Figure 14. Remove the nut on the copper stud (BAT) terminal of the main circuit breaker.
    4. Add the ring terminal on the white power lead and install the nut.
  2. For 2004 and later models:
    1. See Figure 15. Route the white wire and connector to the B+ connector [160B] (1).
    2. Mate the connector halves.
  3. Secure any excess wire with cable straps.
Figure 14. Electrical Panel and Main Circuit Breaker (2003 FXST shown)
1B+ connector
Figure 15. B+ connector [160B] (2004 FXST shown)
Ground the Auxiliary Lamps
  1. See Figure 16. Route the ground wire (BK) (1) to the ground stud or any good electrical ground point.
  2. Remove the nut and add the ring terminal to the ground stud. Tighten the bolt.
Return the Motorcycle to Service
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)
1. Connect the battery cables, positive (+) battery cable first, following the instructions in the appropriate 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)
2. Turn the IGNITION switch to ON and test the auxiliary lamp switch and the lamps for operation.
3. Aim the lamps forward, then tighten the lamp mounting nuts securely.
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)
4. Follow the instructions in the appropriate Service Manual to install the seat.
1Ground wire
Figure 16. Ground Wire Location
SERVICE PARTS
Figure 17. Service Parts: Springer Auxiliary Lamp Kit
Table 1. Service Parts: Springer Auxiliary Lamp Kit
Item
Description (Quantity)
Part Number
1
Auxiliary lamp housing (2)
68683-02
2
Wire harness
69104-04
3
Belleville washer (2)
6072
4
U-clamp (2)
58114-88
5
Bevel washer (4)
58115-88
6
Flat washer (2)
6333
7
Bracket, auxiliary lamp support
68781-88A
8
Hole plug, chrome
68844-05
9
Cap screw, hex socket, 3/8-16 x 2-1/2 in. long
4032A
10
Spacer, 0.09 in. (2.3 mm) thick (2)
5791
11
Screw, hex socket, button head, 5/16-24 x 7/8 in. long
4387
12
Lockwasher, 5/16 in. internal tooth (2)
7127
13
Cable strap, 7.5 in. (190 mm) (4)
10006
14
Cable strap, 5.5 in. (140 mm) (2)
10065
15
Butt splice connector, blue (3)
70586-93
16
Harness retainer (2)
70345-84
17
Conduit, black vinyl, 18 in. (45.7 cm)
68781-88A
18
Bezel trim ring (2)
68725-62A
19
Screw (2)
3514
20
Nut (2)
7606
21
Inner nesting ring
68331-02
22
Shrink tube
72266-94
23
Ring terminal, pre-insulated
9858
24
Boot, switch
67880-94
25
Bracket, switch
70371-00
26
Nut, acorn (2)
7892
27
Label, lamp switch (HDI)
Not Sold Separately
28
Switch
70370-00
29
Relay (not shown)
31504-91B
30
Relay connector housing, 5 cavity (not shown)
72046-79
31
Connector housing, 1 cavity (not shown)
72100-04
32
Fuse (not shown)
72107-04