LED LIGHT KITS FOR POLICE TOUR-PAK
J050882010-03-16
GENERAL
Kit Number
69705-10, 69816-10, 69940-10, 69941-10
Models
Table 1. Kit Descriptions
Kit | Description |
|---|---|
69705-10 | Auxiliary Stop/Tail/Turn Signal Light Kit |
69816-10 | Tour-Pak LED Light Kit (Red) |
69940-10 | Tour-Pak LED Light Kit (Blue) |
69941-10 | Tour-Pak LED Light Kit (Red/Blue Split) |
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
These accessories must be removed when vehicle is sold for non-police use. Follow all applicable federal, state and local regulations when changing to a civilian vehicle.
Additional Parts Required
Separate purchase, and prior or concurrent installation of a current or past model Harley-Davidson Police Tour-Pak® is required for proper installation of these LED lights on this model motorcycle. See the Harley-Davidson Police and Fleet Motorcycle catalog or the Police and Fire/Rescue section of www.harley-davidson.com (English only) for a list of currently available Police Tour-Paks for your model.
Installing kit 69705-10 on Police Tour-Pak 53634-04 or 53637-04 (that previously used a red brake light) will require separate purchase of a wire harness (H-D Part No. 72640-10).
Installing kits 69816-10, 69940-10 or 69941-10 on Police Tour-Pak 53631-04 or 53632-04 (that previously used LED lights with a four hole
mounting pattern) will require separate purchase of the following items:
Table 2. Add for Four-Hole LED Replacement
Description (Quantity) | Part Number |
|---|---|
LED light bezel (trim piece) (One for each light) | 72641-10 |
Washer (Two for each light) | 6789 |
Switch boot | 67880-94 |
Wire harness | 70697-10 |
RTV or other suitable sealing material | 99650-02 |
INSTALLATION ON CURRENT-MODEL TOUR-PAKS
Installing kits 69816-10, 69940-10 or 69941-10 on H-D Police Tour-Pak
54179-10 or 54180-10:
| 1. | See Figure 3. Insert the LED light connector (7) through the large hole (B) in the Tour-Pak (A) side or rear wall. Use the lettering molded in the LED lens for correct orientation of the light. NOTE Install an anchor clip (F) onto the screw threads of the leftmost screw as shown, on the inside of the Tour-Pak, before fastening the nut. | |
| 2. | Secure the LED light to the Tour-Pak using two screws (10) and nuts (11), and the anchor clip. | |
| 3. | Tighten the screws to 1 N·m (9 in-lbs). | |
| 4. | Connect the six-way Deutsch LED light socket housing (7) to one of the mating pin housings on the Tour-Pak wiring harness. | |
| 5. | Slide the socket housing onto the anchor clip to secure the wiring to the inside wall of the Tour-Pak. | |
| 6. | Repeat Steps 1 through 5 for the remaining LED lights. | |
| 7. | Install the Tour-pak to the motorcycle per the Police Tour-Pak instruction sheet. | |
| 8. | Connect the Police Tour-Pak Harness to the main wire harness and the rear lighting wire harness per the Police Tour-Pak instruction sheet. | |
| 9. | Secure the wire harness to the vehicle using cable straps (not supplied). | |
 CAUTIONDo not look directly at LED lights while they are on. Momentary blindness and/or eye damage could result. (00609b) | ||
| 10. | Check the operation of the LED lights. Turn the ignition key switch to IGNITION, but do not start the motorcycle. Slide the OFF/AUX/PURS switch on the right-side handlebar control to AUX to activate the Tour-Pak LED lights. Multiple flasher patterns are available with these lights. To change the flasher pattern, press and release the push button (C) on the right side of the Tour-Pak. Continue pressing and releasing the button to cycle through the available flasher patterns until the desired pattern displays. |
INSTALLATION ON PAST-MODEL TOUR-PAKS
Installing kit 69705-10 on a Police Tour-Pak 53634-04 or 53637-04 that
originally used a red brake light:
| 1. | Disconnect the currently installed LED brake light bar from the wire harness inside the Tour-Pak. NOTE To allow removal of the brake light from the Tour-Pak, the six-way AMP socket housing must be removed from the brake light harness on the
light. There is no need to remove the pin housing on the brake light wiring harness inside the Tour-Pak. | |
| 2. | Remove the six-way socket housing from the brake light wires per the AMP Multilock Connectors section of the service manual. Discard the socket housing. | |
| 3. | Remove the brake light and discard it. Save the mounting hardware (D and E). See Figure 3. | |
| 4. | Remove the brake light wiring harness from the Tour-Pak. | |
| 5. | Locate the other end of the brake light wiring harness on the vehicle. Disconnect the brake light wiring harness from the auxiliary connector and discard it. | |
| 6. | Get the new stop/tail/turn signal (STT) wiring harness (Item K, H-D Part No. 72640-10, sold separately), and feed the end with five loose wires up into the Tour-Pak through the port used by the original harness. | |
| 7. | One at a time, feed the wires from the new auxiliary STT light (1) through the oblong hole (G) on the left rear of the Tour-Pak Install the new STT light using the hardware (D and E) saved in Step 3. | |
| 8. | Tighten the screws to 1 N·m (9 in-lbs). |  Figure 1. Wiring Diagram; Auxiliary Stop/Tail/Turn Signal 69705-10 on Police Tour-Pak 53637-04 or 53634-04 |
| 9. | Insert the five wires and terminals on the light assembly into the correct cavities of the six-way socket housing (3) as follows: |
- Green wire to cavity 1
- White wire to cavity 2
- Yellow wire to cavity 3
- Cavity 4 is left open.
- Red wire to cavity 5
- Brown wire to cavity 6
Also refer to the wiring diagram, Figure 1.
- Plug the socket housing into the mating pin housing on the STT light wiring harness (K).
- Locate the rear lighting wiring harness on the vehicle. Disconnect the rear lighting harness from the main vehicle harness. Route the STT light wiring harness from the Tour-Pak along the left upper frame tube to the disconnected vehicle harnesses. Connect the STT light wiring harness to the main wire harness and rear lighting wire harness.
- Test the STT light for proper operation: This light has a built-in momentary flash feature. Federal Motor Vehicle Safety Standard #108 does not allow flashing red rear lights. Approved law enforcement agencies must obtain a waiver deviating from this standard. To disable this feature and change to a standard tail light/brake light operation: Short across the two prongs again to enable the flash pattern.
- Turn the ignition key switch to IGNITION, but do not start the motorcycle.
- With the ignition key switch ON, The CENTER section is illuminated, along with the vehicle tail lamp.
- With brake lever or brake pedal actuation, the CENTER section will brighten, along with the vehicle tail lamp.
- With left or right turn signal actuation, the end sections FLASH, along with the vehicle turn signal lamps.
- Loosen the lens by partially undoing the two mounting screws.
- Pull the lens away from the light base, exposing the two prongs on the LED board, above the right-hand screw
- Momentarily short across the two prongs with a flat blade screwdriver or similar metallic tool.
Installing kit 69816-10, 69940-10 or 69941-10 on a Police Tour-Pak
53631-04 or 53632-04 that originally used LED lights with a four hole mounting
pattern:
| 1. | Disconnect the currently installed LED lights from the lighting ballast. | |
| 2. | Remove the LED lights from the Tour-Pak, and discard the lights and mounting hardware. | |
| 3. | Remove and discard the lighting ballast assembly. | |
| 4. | Remove the Tour-Pak LED light wiring harness from the Tour-Pak. | |
| 5. | Locate the other end of the Tour-Pak LED light wiring harness on the vehicle. Disconnect the Tour-Pak LED light wiring harness from the auxiliary connector and discard it. | |
| 6. | Using a 13 mm (½ in) diameter drill bit, drill out the two countersunk holes at each of the LED light locations. | |
| 7. | Measure approximately 50 mm (2.0 in) up and 44 mm (1.75 in) to the rear of the power outlet on the right side of the Tour-Pak. Drill a 1.5 mm (1/16 in) diameter pilot hole. Drill a 9.5 mm (⅜ in) diameter hole at the pilot hole for installation of the flasher pattern switch. | |
| 8. | Plug the four holes previously used for each LED light using RTV Sealant (H-D Part No. 99652-0) or other suitable sealing material. NOTE Note the wire colors and positions in each cavity of the six-way LED light socket housing before removal. | |
| 9. | See Figure 3. Remove the six-way socket housing (7) from the wires of one of the LED lights (4) per the Deutsch Connector section of the service manual. Insert the light into an LED light bezel (Item H, trim piece, H-D Part No. 72641-10, available separately). Insert the LED light wires through the large hole (B) in the Tour-Pak (A) side or rear wall. Use the lettering molded in the LED lens for correct orientation of the light. NOTE Install an anchor clip (F) onto the screw threads of the leftmost screw as shown, on the inside of the Tour-Pak over the fender washer, before fastening the nut. | |
| 10. | Install the LED light using the hardware supplied. Use a fender washer (Item I, H-D Part No. 6789, available separately) at each 13 mm (½ in) diameter hole. Tighten the screws to 1 N·m (9 in-lbs). | |
| 11. | Refer to the removal notes and service manual, and insert each socket terminal back into the correct cavity of the socket housing. Slide the socket housing onto the anchor clip to secure the wiring to the inside wall of the Tour-Pak. | |
| 12. | Repeat Steps 9 through 11 for the remaining LED lights. | |
| 13. | Get the new LED light wiring harness (Item J, H-D Part No. 70697-10, sold separately). Feed the bare terminals on one end of the harness, from the inside, through the unused port in the floor of the Tour-Pak. NOTE Refer to the wiring diagram, Figure 2. Cavity numbers are molded into the pin and socket housings. | |
| 14. | Refer to the AMP Multilock Connectors section of the service manual. Insert the six AMP socket terminals on the end of the wire harness to the eight-way socket housing that came with the harness as follows: |
- Brown wire to cavity 1
- Orange/White wire to cavity 2
- Violet wire to cavity 3
- Cavity 4 is left open.
- Black wire to cavity 5
- Red/Yellow wire to cavity 6
- Blue wire to cavity 7
- Cavity 8 is left open.
- Insert the six AMP pin terminals to the eight-way pin housing following the above sequence.
- Refer to the Deutsch Connectors section of the service manual. Insert the two pin terminals on the end of the wire harness to the two-way pin housing as follows:
- Green/Red wire to cavity 1
- Black wire to cavity 2
Lock the terminals with the secondary lock included.
| 15. | Locate the rear lighting wiring harness on the vehicle. Disconnect the rear lighting harness from the main vehicle harness. Route the LED light wiring harness from the Tour-Pak along the left upper frame tube to the disconnected vehicle harnesses. Connect the LED light wiring harness to the main wire harness and rear lighting wire harness. | |
| 16. | Insert the push button switch (C) through the hole in the Tour-Pak. Secure the push button with the rubber boot (H-D Part No, 67880-94, purchased separately). | |
| 17. | Connect the individual six-way Deutsch LED light socket housings to the mating pin housings on the new LED light wiring harness. See Figure 2 | |
| CAUTION Do not look directly at LED lights while they are on. Momentary blindness and/or eye damage could result. (00609b) | ||
| 18. | Check the operation of the LED lights. a. Turn the ignition key switch to IGNITION, but do not start the motorcycle. b. Select AUX on the right-side handlebar pursuit switch to activate the Tour-Pak LED lights. c. Multiple flasher patterns are available with these lights. To change the flasher pattern, press and release the push button on the right side of the Tour-Pak. Continue pressing and releasing the button to cycle through the available flasher patterns until the desired pattern displays. |
CARE AND MAINTENANCE
Use only soap and water to clean the lenses. Use of other chemicals could result in premature lens cracking (crazing) and discoloration. Do not use a pressure washer to clean this product.
Figure 2. Wiring Diagram; LED Lights 69816-10, 69940-10 or 69941-10 on Police Tour-Pak 53631-04, 53632-04, 54179-10 or 54180-10
SERVICE PARTS
Figure 3. Service Parts, LED Light Kits for Police Tour-Paks
Table 3. Service Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
69705-10 Auxiliary Stop/Tail/ Turn Signal Light | 1 | Light assembly (includes items 2 and 3) | Not sold separately |
2 |
| 73191-96 | |
3 |
| 73156-96BK | |
Tour-Pak LED Kit 69816-10 (Red) . Kit 69940-10 (Blue) . Kit 69941-10 (Red/Blue Split) | 4 | LED light (Flasher unit), M7 series (includes items 5 through 11) | Not sold separately |
5 | Gasket | Not sold separately | |
6 | Socket terminal, Deutsch (5) | 72116-94BK | |
7 | Socket housing, Deutsch, six-way | 72116-94BK | |
8 | Seal pin (plug) | 72195-94 | |
9 | Secondary lock | 72156-94 | |
10 | Screw, pan head Phillips, #6-32 x 31.75 mm (1.25 in) (2) | Not sold separately | |
11 | Hex nut, with lockwasher (2) | 7889 | |
Items mentioned in text, but not included in kit: | |||
A | Police Tour-Pak | ||
B | Hole (3) in Tour-Pak side and rear walls | ||
C | Flasher pattern push button (with rubber boot) on Tour-Pak right side | ||
D | #6-32 x 41.3 mm (1⅝ in) long pan head screw (2) | ||
E | #6-32 hex nut with external-tooth lockwasher (2) | ||
F | Anchor clip, Part No. 72199-94 (3, from Tour-Pak Kit) | ||
G | Oblong hole on Tour-Pak left rear | ||
H | LED light bezel (trim piece), H-D Part No. 72641-10 | ||
I | Fender washer, H-D Part No. 6789 | ||
J | LED lights wiring harness, H-D Part No. 70697-10 | ||
K | Stop/tail/turn signal (STT) wiring harness, H-D Part No. 72640-10 | ||