POLICE EMERGENCY RESPONSE KITS
J046502008-08-20
GENERAL
Kit Numbers
91446-00A, 91447-00A, 91453-00A
Models
For model fitment information, see the Harley-Davidson Police and Fleet Motorcycle catalog or the Police and Fire/Rescue section of www.harley-davidson.com (English only).
NOTE
This accessory must be removed when the vehicle is sold for non-police use. Follow all applicable federal, state and local regulations when changing to a civilian vehicle.
Tools and Supplies Required
Loctite® 271 Threadlocker and Sealant - Red (H-D Part Number 99671-97) is required for the proper installation of this kit.
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 and a Police Models Service Manual Supplement for this year and 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)
Police Emergency Response Kits 91446-00A or 91447-00A require up to 10.65 amps additional current from the electrical system.
Police Emergency Response Kit 91453-00A requires up to 8
amps additional current from the electrical system.
INSTALLATION
Models with main FUSE:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the service manual and follow the instructions given to remove the main fuse.
Models with main CIRCUIT BREAKER:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the service manual and follow the instructions given to disconnect the negative (black) battery cable from the negative (-) battery terminal.
For Kit 91453-00A: Proceed to Install
Siren/Speaker.
For Kit 91446-00A or 91447-00A:
Install Pole Lamp
| 1. | Refer to the Police Models service manual supplement for instructions to remove the left-side saddlebag. For 2008 and earlier models: Remove and discard the original equipment (OE) grommet in the upper pole lamp mounting plate. For ALL models: Install the grommet supplied with the new pole lamp. NOTE The rear emergency lamp branch of the vehicle main harness can be accessed at the left rear of the vehicle frame forging. | |||||||||||||
| 2. | See Figure 4. Unthread the ring (2) from the bottom of the pole lamp (1) and set it aside. | |||||||||||||
| 3. | Cut the wires extending from the bottom of the pole to a length of approximately 14 inches (356 mm). Refer to the service manual and follow the instructions given to crimp the Deutsch pin terminals (3) to the red and black pole lamp wires. | |||||||||||||
| 4. | Locate the two-way Deutsch socket housing [59B] on the siren amplifier and strobe harness. Note the cavity locations of the wires (should be green/red in cavity 1, black in cavity 2. | |||||||||||||
| 5. | Obtain the two-way Deutsch pin housing (4) and secondary lock (5) from the pole lamp kit. See the instructions in the service manual to install the red wire and pin terminal from the pole lamp into the cavity that will mate with the green/red wire in socket housing [59B]. Install the black wire and terminal into the cavity that will mate with the black wire. | |||||||||||||
| 6. | Insert the wire harness and pole down through the grommet in the luggage rack. Apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the pole if needed. | |||||||||||||
| 7. | For 2009 and later models: Loosely assemble the lower pole lamp bracket (1) to the saddlebag guard rails (2) with U-bolts (3) and flange nuts (4). Insert the wires and the bottom of the pole through the hole in the bracket. | 
Figure 1. Lower Pole Lamp Bracket Installation | ||||||||||||
| 8. | Apply a few drops of Loctite 271 - Red to the clean ring (6) threads. Thread the ring, beveled side DOWN, onto the bottom of the pole. Tighten the ring finger-tight, then an additional 1/2-turn to secure the pole to the bracket. | |||||||||||||
| 9. | Tighten the U-bolt flange nuts to 6.8–9.5 N·m (5–7 ft-lbs) Connect the pole lamp pin housing to socket housing [59B]. Secure the rear emergency lamp wiring to the saddlebag support bracket with cable straps (not supplied) |
Install Siren/Speaker
| 1. | See Figure 4. Position the speaker mounting bracket (18) onto the siren/speaker (13) horn, aligning the mounting holes. | |||||||
| 2. | Install first a flat washer (20), then a rubber washer (19) onto the threads of each 1/4-20 hex head bolt (21) from the siren/speaker mounting kit (17). From the outside, insert the bolt threads through the holes in the speaker mounting bracket and the speaker horn. | |||||||
| 3. | Assemble a second rubber washer, then another flat washer onto the threads of each bolt, and thread a 1/4-20 flanged locknut (22) onto each bolt. Tighten each bolt and nut uniformly and securely until the four rubber washers are slightly and equally deformed. DO NOT OVERTIGHTEN. | |||||||
| 4. | Position the speaker mounting bracket inside the upper corner of the right-side engine guard. Install the U-bolts (23) over the engine guard and through the holes in the bracket. Install the 5/16-18 flanged locknuts (24) onto the U-bolt threads, and tighten securely. | |||||||
| 5. | See Figure 2. A sticker (3) on the speaker magnet housing (2) identifies the location of the speaker drain hole. With the speaker mounted to the engine guard, verify that the drain hole sticker is positioned at the bottom of the speaker magnet housing. If the drain hole is NOT correctly positioned, proceed as follows: a. Loosen the speaker cone (1) by turning the cone counterclockwise. b. Rotate the speaker magnet housing so the drain hole sticker is positioned at the bottom. c. Hold the magnet housing in position, and turn the cone clockwise to tighten. | 
Figure 2. Speaker Cone, Magnet Housing and Drain Hole | ||||||
| 6. | Refer to the service manual and follow the instructions given to crimp the Deutsch pin terminals (14) to the black siren wires. | |||||||
| 7. | Obtain the two-way Deutsch pin housing (15) and secondary lock (16) from the siren/speaker kit. See the instructions in the service manual to install the terminals from the speaker horn into the pin housing cavities. NOTE The siren branch of the siren amplifier and strobe harness can be accessed at the right side of the vehicle, forward of the fuel tank and above the engine guard. | |||||||
| 8. | Locate the two-way Deutsch socket housing [57B] on the siren amplifier and strobe harness. Both wires are gray/red. | |||||||
| 9. | Connect the speaker horn pin housing to socket housing [57B]. Secure the speaker wiring to the engine guard with cable straps (not supplied). |
Install Siren Amplifier
| 1. | Position the top loop of the amplifier bracket (29) over the leading edge of the left-side upper saddlebag guard rail. Align the spacer (30) with the holes inside the loop. Place the washer (32) onto the threads of the hex head cap screw (31), insert the screw through the top hole in the amplifier bracket and the spacer. Thread the screw into the weld nut, but do not fully tighten. | |
| 2. | With the loop rearward and the mounting hole up, install the P-clamp (33) onto the lower saddlebag guard rail. Align the clamp to the bottom hole in the amplifier bracket. Thread the wing screw (34) through the clamp into the weld nut, but do not fully tighten. | |
| 3. | Align the siren amplifier (25) mounting slots with the four holes in the amplifier bracket. Assemble the amplifier to the bracket with four 1/4-24 button head screws (26) and flat washers (27), and tighten to 8 N·m (6 ft-lbs). NOTE To prevent scratching the paint, avoid contact with the vehicle side cover while tightening the amplifier bracket fasteners. | |
| 4. | Align the amplifier bracket squarely on the saddlebag guard rails. Tighten the top mounting screw securely. Tighten the bottom wing screw securely. NOTE The amplifier branch of the siren amplifier and strobe harness can be accessed above the left side cover. A light coat of liquid soap, window cleaner or all-purpose lubricant may be needed to slide the connector boot into place. | |
| 5. | Connect the 18-way Packard socket housing [72B] on the siren amplifier and strobe harness to the pin housing on top of the amplifier. Slide the boot down securely over the connectors. Secure the amplifier wiring to the upper portion of the left-side saddlebag guard with cable straps (not supplied). |
Install Microphone
- Mount the microphone hanger (37) in a convenient location using the screws (38), washers (39) and locknuts (40) from the microphone mounting kit.
- Insert the microphone plug into the jack located on the left side of the nacelle (FLHP models) or to the left of the glove box (FLHTP models).
Return to Service
- Verify that the ignition/key switch is turned to the OFF position. Models with main FUSE: Refer to the service manual and follow the instructions given to install the main fuse. Models with main CIRCUIT BREAKER: Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal. Refer to the service manual and follow the instructions given to attach the negative battery cable.
- Turn the ignition/key switch to IGNITION, but do not start the motorcycle.
- To adjust the radio repeat levels (output volume):
- Locate the PA adjustment port (potentiometer) to the left of the twelve-position input port on the remote amplifier. The potentiometer is hidden behind a #10-32 Phillips head machine screw (see Figure 3 ). Remove this screw.
- Key the microphone, and place it near the speaker.
- Insert the screwdriver in the PA adjustment port and turn in a clockwise direction to increase the volume until no noticeable feedback distortion is heard.
- Return the Phillips head screw to its original position
- Test for proper operation of installed systems.
NOTE
Before using the WPA™ series water-proof amplifier, the Public Address system (PA) output volume must be adjusted to satisfactory operating levels.
To adjust this level, a small, flat blade screwdriver is needed.
Figure 3. Amplifier (Rear View)
SERVICE PARTS
Figure 4. Service Parts, Police Emergency Response Kits
SERVICE PARTS
Table 1. Service Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 91446-00A Police Emergency Response, with Blue Pole Lamp | 1 | Pole lamp assembly, with blue lens | Not sold separately |
2 | Ring, pole attachment | Not sold separately | |
3 | Pin terminal, Deutsch, #16-18 AWG (2) | 72190-94 | |
4 | Pin housing, Deutsch, two-way, sealed | 72102-94BK | |
5 | Secondary lock, Deutsch two-way pin housing | 72142-94 | |
6 | Lens, pole lamp (blue) | 67688-88 | |
7 | Bulb, flash tube | 67598-88 | |
8 | Lower pole mounting kit (includes items 9 through 11. See Table 2.) | 91379-09 | |
12 | Siren/speaker kit (includes items 13 through 16. See Table 2.) | 91157-88A | |
17 | Siren/speaker mounting kit (includes items 18 through 24. See Table 2.) | 91154-87 | |
25 | Amplifier, siren/speaker, 100W | 91156-93 | |
26 | Screw, button head, 1/4-24 x 1-3/4 inch (44 mm) long (4) | 4365 | |
27 | Flat washer, 1/4 inch (6 mm) ID | 6703 | |
28 | Amplifier mounting kit (includes items 29 through 34. See Table 2.) | 91260-93A | |
35 | Microphone kit (includes items 36 through 40. See Table 2.) | 91448-00 | |
Kit 91447-00A Police Emergency Response, with Red Pole Lamp | 1 | Pole lamp assembly, with red lens | Not sold separately |
2 | Ring, pole attachment | Not sold separately | |
3 | Pin terminal, Deutsch, #16-18 AWG (2) | 72190-94 | |
4 | Pin housing, Deutsch, two-way, sealed | 72102-94BK | |
5 | Secondary lock, Deutsch two-way pin housing | 72142-94 | |
6 | Lens, pole lamp (red) | 67599-88 | |
7 | Bulb, flash tube | 67598-88 | |
8 | Lower pole mounting kit (includes items 9 through 11. See Table 2.) | 91379-09 | |
12 | Siren/speaker kit (includes items 13 through 16. See Table 2.) | 91157-88A | |
17 | Siren/speaker mounting kit (includes items 18 through 24. See Table 2.) | 91154-87 | |
25 | Amplifier, siren/speaker, 100W | 91156-93 | |
26 | Screw, button head, 1/4-24 x 1-3/4 inch (44 mm) long (4) | 4365 | |
27 | Flat washer, 1/4 inch (6 mm) ID | 6703 | |
28 | Amplifier mounting kit (includes items 29 through 34. See Table 2.) | 91260-93A | |
35 | Microphone kit (includes items 36 through 40. See Table 2.) | 91448-00 | |
Kit 91453-00A Police Emergency Response, with no pole lamp | 12 | Siren/speaker kit (includes items 13 through 16. See Table 2.) | 91157-88A |
17 | Siren/speaker mounting kit (includes items 18 through 24. See Table 2.) | 91154-87 | |
25 | Amplifier, siren/speaker, 100W | 91156-93 | |
26 | Screw, button head, 1/4-24 x 1-3/4 inch (44 mm) long (4) | 4365 | |
27 | Flat washer, 1/4 inch (6 mm) ID | 6703 | |
28 | Amplifier mounting kit (includes items 29 through 34. See Table 2.) | 91260-93A | |
35 | Microphone kit (includes items 36 through 40. See Table 2.) | 91448-00 |
SERVICE PARTS
Table 2. Service Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Item 8. Lower Pole Mounting Kit 91379-09 | 9 | Bracket, pole lamp lower mounting | Not sold separately |
10 | U-bolt (2) | 4803 | |
11 | Flange nut (4) | 7717 | |
Item 12. Siren/Speaker Kit 91157-88A | 13 | Siren/speaker, 100W | Not sold separately |
14 | Pin terminal, Deutsch, #16-18 AWG (2) | 72190-94 | |
15 | Pin housing, Deutsch, two-way, sealed | 72102-94BK | |
16 | Secondary lock, Deutsch two-way pin housing | 72142-94 | |
Item 17. Siren/Speaker Mounting Kit 91154-87 | 18 | Bracket, siren/speaker mounting | 91127-85 |
19 | Rubber washer (4) | 6035A | |
20 | Flat washer (4) | 6036 | |
21 | Cap screw, hex head, 1/4-20 x 3/4 inch (19 mm) long (2) | 3787 | |
22 | Flanged locknut, 1/4-20 (2) | 7716 | |
23 | U-bolt (2) | 91159-82 | |
24 | Flanged locknut, 5/16-18 (4) | 7531 | |
Item 28. Amplifier Mounting Kit 91260-93A | 29 | Bracket, amplifier mounting | Not sold separately |
30 | Spacer | Not sold separately | |
31 | Cap screw, hex head | 2871W | |
32 | Flat washer | 6237 | |
33 | P-clamp | 28867-88 | |
34 | Wing screw, 5/16-18 | 2979 | |
Item 35. Microphone Kit 91448-00 | 36 | Microphone, WS-320 | 76185-93 |
37 | Hanger, microphone | 76201-80A | |
38 | Machine screw, pan head (2) | 2659 | |
39 | Flat washer (2) | 6716 | |
40 | Hex locknut (2) | 7624 |