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BLACK FAN KIT AND CHROME FAN KITS FOR TOURING MODELS
J024142009-03-04
GENERAL
Kit Number
91531-00D (black) and 91550-00C (chrome)
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
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.
Kit Contents
See Figure 8 and Table 1.
NOTE
A horn is required for compliance with most state's laws and for operation in many parts of the world. For 1997-1999 model motorcycles, it will be necessary to purchase and install horn kit 69060-90D prior to installation of the accessory fan. This kit is available at your H-D Dealer.
INSTALLATION
1. Refer to service manual and remove seat.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
2. Disconnect battery negative cable.
Relocate Stock Horn (FLHT)
NOTE
This cooling fan is designed to provide supplemental cooling for motorcycles subjected to long periods of idling/parade duty. The fan is mounted on the left side of the engine in the area where the horn is mounted. The horn must be removed and relocated.
1. Follow service manual instructions to remove horn and bracket.
2. Disconnect wires from horn and remove large nut that secures horn to horn bracket. Set horn aside. Discard horn isolator.
3. Follow service manual instructions to remove outer fairing.
4. See Figure 1. Locate connector (3), refer to service manual, Appendix A, Deutsch Electrical Connectors. Follow directions given and remove socket terminal from cavity 6 (yellow/ black wire). Cut socket terminal from wire and cover wire end with electrical tape.
5. See Figure 8. Locate horn relocation harness (21) from kit.
1Right support bracket
2Horn bracket mounting point
3Connector
4Cigarette lighter
Figure 1. Behind Outer Fairing (FLHT models)
6. See Figure 1. Insert socket terminal (on yellow/black wire) of horn relocation harness into cavity 6 of connector [2B] (3). Plug two halves of connector together.
7. Route black wire with double spade terminal (on horn relocation harness) to cigarette lighter. Disconnect black wire from cigarette lighter. Connect double spade terminal to cigarette lighter and reconnect stock black wire on the "open" double spade terminal.
8. Connect the two remaining terminals on the horn relocation harness to the horn terminals. The horn is not polarity sensitive so leads may be attached to either horn terminal.
9. See Figure 8. Locate two horn brackets (11) and flat rubber washer (7). Slip rubber washer on horn stud. Take two horn brackets and install large hole end on horn stud. Secure with metric M6 nut (13).
10. Mount horn to right support bracket with 10-24x1/2 screw (4) and washer (10). Thread screw into PEM nut. If right support bracket does not have PEM nut, drill a 7/32 inch hole at the location shown in Figure 2 and use 10-24 nut (14), washers (10) and screw (4) to mount horn.
11. Position horn so horn cover opening is facing down.
12. Cover terminals on stock horn leads with electrical tape and position leads so they will not be damaged. Secure leads with a cable strap if necessary.
11 to 1 1/16 inch (43 mm)
2PEM nut or 7/32 inch (5.56 mm) hole
Figure 2. Horn Mounting Hole Location (FLHT Models)
Relocate Stock Horn (FLHR)
  1. Follow service manual instructions to remove horn and its bracket.
  2. Disconnect wires from horn and remove large nut that secures horn to horn bracket. Remove horn from chrome cover. Set horn aside.
  3. For 1999 and later FLHR. See Figure 8. Locate three horn brackets (11) and flat rubber washer (7). Slip rubber washer on horn stud. Take three horn brackets and install large hole end on horn stud. Secure with metric M6 nut (13).
  4. Remove left front fuel tank TORX® screw.
  5. Mount horn (without chrome cover) at left front of fuel tank with TORX screw.
  6. Position horn so horn cover opening is facing downward.
  7. Route stock horn wires forward and reconnect to horn.
Remove Stock Upper Engine Mounting Bracket
  1. Remove screw securing rear of fuel tank and gently raise fuel tank to gain access to upper engine mounting bracket. Place suitable blocking under tank.
  2. Remove bolt attaching stabilizer link to upper engine mounting bracket.
  3. Remove two bolts and washers securing upper engine mounting bracket to front and rear cylinder heads. Retain bolts and washers for attaching new upper engine mounting bracket from kit.
  4. Note position of fuel hose. Remove upper engine mounting bracket.
1Main circuit breaker
2Silver post
3Accessory connector
Figure 3. 2003 and Earlier Under Seat
Connect Accessory Fan Harness
1. Connect fan harness power lead to power source. For 2003 and earlier: See Figure 3. For 2004 and later: See Figure 4.
a. Connect ring terminal on accessory fan harness to silver stud on main circuit breaker.
b. Locate the B+ connector under the seat.
c. See Figure 8. Mate the kit wire harness B+ adapter (19) to the B+ connector.
d. Cut the ring terminal off the lead (fuseholder lead) of the fan harness and cut the length of the B+ adapter lead to reach the end of the fuseholder lead on the fan harness.
e. Strip 3/8 inch wire from the ends of the leads and follow Service Manual instructions in "SEALED BUTT SPLICE CONNECTORS" to crimp and heat connector (18) to spice lead of the B+ adapter lead to the fuse holder lead on the wire harness.
2. Connect socket connector [4B] on accessory fan harness ( Figure 7 ) to pin connector [4A] on accessory connector (2) ( Figure 4 ).
NOTE
Due to the different air cleaner backplate configurations, take care to mount the thermostat in a suitable location in the next step. Make certain thermostat will not contact cylinder head or prevent normal mounting of backplate. Orient thermostat so its leads are routed away from components that could damage them.
1Ground stud
2Accessory connector
3B+ connector
Figure 4. 2004 and Later Under Seat
1Backplate
2Thermostat
Figure 5. Thermostat Mounting
Figure 6. Grind Spotface (primary cover removed to show location)
3. See Figure 5. Follow Service Manual instructions to remove air cleaner backplate.
4. Position the thermostat (part of accessory fan harness) on backplate to rear of intake and described in "NOTE" above. Mark thermostat mounting hole locations on backplate.
5. Drill two 5/32 inch holes in backplate.
6. See Figure 8. Mount thermostat with 6-32x3/8 inch screws (3) and nuts (6).
7. Mount fan relay in a vertical position (mounting hole up) to a stable position on the frame that allows adequate seat clearance. Depending on model year application, secure in an open relay socket with an existing (stock) mounting screw, or secure with a cable strap from kit.
Mount Fan Assembly
1. See Figure 8. Install fan mount (2) (upper engine mounting bracket from kit) on front and rear cylinder heads and secure with stock bolts and washers. Tighten bolts to 38–47.5 N·m (28–35 ft-lbs).
2. Install upper stabilizer link on upper engine mounting bracket with stock bolt and washer.
3. Secure stabilizer link with stock bolt, nut and washer. Tighten bolt to 24–30 N·m (18–22 ft-lbs).
4. Insert rubber mount stud (8) through mounting hole in fan mount (2) and secure with 1/4 in ID washer (9) and 1/4-20 nut (17). Tighten nut to 8–11 N·m (72–96 in-lbs).
NOTE
When tightening the locknuts on the rubber mounts, do not allow the rubber mounts to twist. Twisted mounts may cause equipment damage.
5. See Figure 8. Insert rubber mount stud (8) through bottom mounting hole in fan cover assembly and secure with 1/4 in ID washer (9) and 1/4-20 nut (6). Tighten nut to 8–11 N·m (72–96 in-lbs).
6. Position fan assembly so holes in upper mounting tabs on fan cover assembly engage rubber mount studs in upper engine mounting bracket.
1Fan harness
2Fan relay and connector
3Lead to fan motor lead
4Lead to fan motor lead
5Thermostat
6FLHT horn relocation harness
7Horn terminal
8Lead (yellow/black) to cavity 6 connector
9Lead to cigarette lighter lead
10Power lead ring terminal
11Accessory connector
12Fuse holder (15 amp)
Figure 7. Wire Harness
7. Install 1/4 inch inside diameter (ID) flat washers (9) and 1/4-20 locknuts (6) on upper studs. Tighten finger tight.
8. Install lower mounting bracket (5), 1/4 inch ID flat washer and 1/4-20 locknut on rubber mount stud. Tighten finger tight.
9. See Figure 6. Remove upper front bolt and washer from inner primary housing. Remove spotface material from primary housing if needed to allow bracket clearance.
NOTE
Grind material from this area as required to allow bracket installation on engines. Bracket should not contact edge of spotface when installed.
10. Insert bolt through lower mounting hole in lower mounting bracket and tighten finger tight. Position lower mounting bracket so rubber mounts are not stressed and tighten upper front bolt to 24–28 N·m (18–21 ft-lbs).
11. Tighten the three 1/4-20 fan mounting nuts to 8–11 N·m (72–96 in-lbs).
  1. See Figure 8. Peel off medallion (16) backing. align logo and affix to hole in cover. Tape is strong and will not allow repositioning.
  2. Route fan motor leads over upper engine mounting bracket (2). Install a cable strap to secure fan motor leads.
    3. NOTE
    Make certain motor leads are connected as specified in the next step. Reversed leads would reverse fan rotation and decrease cooling efficiency which could cause engine damage.
  3. See Figure 7. Connect motor leads to the sealed butt connectors on the accessory fan harness. Connect as follows:
  • Black fan motor lead to Black harness lead.
  • Blue fan motor lead to Blue/Black harness lead.
  1. Follow service manual instructions in "SEALED BUTT SPLICE CONNECTORS" to crimp and heat connectors to melt the sealant.
  2. See Figure 8. Cable strap (1) fan motor leads to fan mount (top engine mount) (2) between the center and left side mounting hardware.
  3. Arrange accessory fan harness under seat so harness and fuseholder will not be pinched/damaged when seat is installed.
  4. Secure harness with cable straps from kit.
Return Motorcycle to Service
1. Carefully remove blocking from under rear of fuel tank and install screw at rear of fuel tank.
2. Reconnect the negative battery cable.
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)
3. Install the seat.
Operation
The cooling fan is thermostatically controlled and will only operate when the thermostat senses cooling air temperature of approximately 140° F (60° C).
Cooling air movement is from left to right. Air is drawn in through slots in the fan cover and blown across the cylinders and cylinder heads.
SERVICE PARTS
Figure 8. Service Parts: Fan Kit for Touring Models
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Cable strap (3)
10065
2
Fan mount (top engine mount)
16317-00
3
Screw, 6-32 x 3/8 inch (2)
2517
4
Screw, 10-24 x 1/2 inch
2592
5
Bracket, lower mounting
29497-00A
6
Nut, 6-32 (2)
60031-61
7
Washer, rubber, 1/4 x 3/4 x 3/64
6265
8
Mount, rubber (3)
62901-00
9
Washer, 1/4 x 5/8 x 1/16 (6)
6703
10
Washer, #10 (2)
6716
11
Horn bracket, straight (3)`
Not Sold Separately
12
Fan assembly
See repair kits below
13
Nut, flanged, M6
7495
14
Nut, 10-24
7624
15
Nut, 1/4-20 (6)
7686
16
Medallion
99598-00
17
Fan cover, black
29498-00A
Fan cover, chrome
29646-00A
18
Splice connector
70586-93
19
Wire harness, B+ adapter
70310-04
20
Existing hardware
21
Wire harness, horn relocation
Not Sold Separately
22
Fan Harness
Not Sold Separately
23
Relay
31504-91A
Repair kits available:
A
Fan motor
74452-00A
B
Thermostat
74453-00
C
Fan cover, black
74454-00B
Fan cover, chrome
74456-00B