VRSC™ TURN SIGNAL RELOCATION KIT
J033412006-06-26
GENERAL
Kit Number
57205-05
Models
This kit fits 2002 and later VRSCA, VRSCB, VRSCD, and VRSCDX model motorcycles.
This kit is a necessary addition when installing Quick Release Windshields 57211-05 or 57177-05 on these model motorcycles.
Installation of this kit will relocate the turn signals to one of the motorcycle's triple clamps.
Additional Parts Required
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 available from a Harley-Davidson Dealer.
INSTALLATION
Removing Turn Signals
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)
| 1. | Remove the 40 amp Maxi-Fuse or disconnect the battery cables, negative cable first. | |||||||||||||||||
NOTICE Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Handle the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210b) | ||||||||||||||||||
| 2. | For VRSCA models, remove headlamp assembly. For VRSCB
models, continue to Step 4. a. While facing the headlamp from behind (looking toward front of motorcycle), reach behind the headlamp bucket and twist the headlamp bulb approximately 45 degrees counterclockwise, then gently pull straight out of the headlamp. Repeat for remaining bulb. Temporarily secure bulbs out of the way for the following steps. b. See Figure 1. Remove the two mounting screws securing the headlamp bracket to the upper triple clamp and remove headlamp assembly. Save hardware. NOTE A bezel hook holds bottom of bezel and top cover to the bottom handlebar cover and can be damaged if forced during removal or installation. If damaged, the cover must be replaced. It is not necessary to remove the instrument bezel from the top cover. | 
Figure 1. Headlamp and Handlebar Top Cover Hardware 
Figure 2. Remove Handlebar Bottom Cover | ||||||||||||||||
| 3. | For VRSCA models, perform the following steps to remove the handlebar cover. a. Remove the two screws securing the handlebar top cover and instrument housing bezel to the handlebar bottom cover. b. From headlamp bracket end of cover, gently tilt the handlebar top cover and bezel up and back to separate from bezel hook, then remove. c. See Figure 2. Remove two screws securing the handlebar bottom cover (2) to the handlebars and gently separate bottom cover from cluster. Proceed to Step 5. | |||||||||||||||||
| 4. | For 2004 and later models, remove left side frame panel. Save hardware. | 
Figure 3. Remove Connector and Turn Signal Wiring (2002-2003 models) 
Figure 4. Remove Turn Signal Connector 31 (2004 models) | ||||||||||||||||
| 5. | Disconnect the turn signal wiring as follows: a. For 2002-2003 models, see Figure 3. Gently pull wiring with instrument cluster away from the handlebars. Locate turn signal connector [31B] and disconnect from socket [31A]. Note left and right turn signal wire locations. Follow instructions in Service Manual under Multilock Electrical Connectors (Socket Terminal Removal/Installation) and remove left and right front turn signal socket terminals from connector. Proceed to Step 6. b. For 2004 and later models, see Figure 4. In the left side frame, locate turn signal connector (2) [31B] and disconnect from socket (1) [31A]. Note left and right turn signal wire locations. Follow instructions in Service Manual under Multilock Electrical Connectors (Socket Terminal Removal/Installation) and remove left (4) and right (3) front turn signal socket terminals from connector. | 
Figure 5. Remove Turn Signal Assemblies | ||||||||||||||||
| 6. | See Figure 5 and perform Steps (a) through (d) to remove each turn signal. a. At turn signal mount under handlebar, loosen jamnut. Hold retainer and loosen ball stud clamp, unthread ball stud and remove turn signal. b. Unthread and discard retainer, but save lock washer. Unthread remaining hardware from turn signal housing and discard. c. Carefully pull turn signal wiring through cable strap attached to handlebar and remove assembly. d. See Figure 10. Obtain acorn nut (7) from kit. Use lock washer saved in Step b, and install acorn nut to secure mirror. Tighten securely. |
Relocating the Turn Signals
NOTE
If this kit is being used in conjunction with Quick Release Detachable Windshields 57211-05 and 57177-05, the turn signals must be installed on the lower triple clamp.
| 1 | Tie Wrap |
Figure 6. Secure Wiring
| 1. | Install each turn signal as follows. a. See Figure 10. Assemble the toothed lock washer (2), relocation stalk (1), lock washer (5) and small cap screw (4) as shown. b. Remove the pinch bolt attached to the back side of the triple clamp. Replace it with the turn signal assembly and larger cap screw (3). Tighten only enough to hold in place. c. Hold motorcycle in upright position and align turn signal to vehicle orientation. Torque turn signal screw to 11–14 N·m (8–10 ft-lbs). d. Torque cap screw (3) to 41–47 N·m (31–34 ft-lbs). e. See Figure 6. Use tie wraps to secure the turn signal wiring to the stalk and triple clamp. | 
Figure 7. Join Wiring 
Figure 8. Turn Signal Wire Routing  Figure 9. Turn Signal Wire Routing | ||||||||||
| 2. | Route the turn signal wiring as follows. a. See Figure 7. Route the wiring for the left and right turn signals in front of the steering head and join together with a tie wrap. Pass the combined wiring under the instrument cluster harness. b. For 2002-2003 models, see Figure 8. Route wiring upward with instrument cluster harness between left and right handlebar control harnesses. Add tie wraps if necessary to secure. Proceed to Step 3. c. For 2004 and later models, see Figure 9. Route wiring on to the left side frame. Add tie wraps if necessary to secure. | |||||||||||
| 3. | Follow instructions in Service Manual under Multilock Electrical Connectors (Socket Terminal Removal/Installation) and install left (3) and right (4) front turn signal socket terminals to the turn signal connector [31B]. Plug the connector into socket [31A]. | |||||||||||
| 4. | Bundle the excess wiring and turn the handlebars all of the way to the right and left to verify free movement. NOTE A bezel hook holds bottom of bezel and top cover to the bottom handlebar cover and can be damaged if forced during removal or installation. If damaged, the cover must be replaced. | |||||||||||
| 5. | For VRSCA models, install handlebar covers as follows: a. Align the handlebar bottom cover over instrument cluster and secure cover to handlebar. b. Orient instrument bezel and handlebar top cover, and fit bezel hook over tab on handlebar bottom cover. Gently press handlebar top cover and instrument housing bezel down until bezel hook snaps into tab. c. Using two screws, align and install handlebar top cover to handlebar bottom cover. Tighten screws to 1.3–1.9 N·m (12–16 in-lbs). | |||||||||||
| 6. | For 2004 and later models, replace left side frame panel, carefully tucking bundle behind. NOTE If this kit is being used in conjunction with Quick Release Windshields 57211-05 and 57177-05, return to Quick Release Detachable Windshield Kit instructions. NOTE The low beam headlamp bulb (labeled H11) mounts in the top hole in the rear of the headlamp assembly. The high beam bulb (labeled H9) mounts in the bottom hole. | |||||||||||
NOTICE Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Handle the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210b) | ||||||||||||
| 7. | For VRSCA models, install the headlamp and bulbs as follows: a. Using two mounting screws saved in Step 2b of Removing the Turn Signals, align and install headlamp bracket to upper triple clamp. Tighten screws to 11–18 N·m (8–13 ft-lbs). b. Gently install each of the headlamp bulbs to back of headlamp and twist approximately 45 degrees clockwise to secure. c. Follow the instructions in the Service Manual to adjust the headlamp for proper visibility. | |||||||||||
| 8. | Refer to the Service Manual and follow the instructions given to re-connect the maxi-fuse. | |||||||||||
| 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) | ||||||||||||
| 9. | Check the turn signals for proper operation. |
SERVICE PARTS
Figure 10. Service Parts: VRSC Turn Signal Relocation Kit
Table 1. Service Parts: VRSC Turn Signal Relocation Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Turn signal relocation stalk (2) | 57198-05 | 5 | Lockwasher, helical 5/16 (2) | 7042 | |
2 | Lockwasher; internal tooth 5/16 (2) | 7127 | 6 | Cable ties (6) (not shown) | 10006 | |
3 | Screw, hex socket head cap 10 mm x 1-1/2 (2) | 3812M | 7 | Acorn nut, 5/16-24 (chrome) (used on mirrors, not shown)(2) | 7736 | |
4 | Screw, hex socket head cap 5/16-24 x 5/8 (2) | 2698A |
NOTE
Appearance of actual components may vary from illustration.