ENGINE GUARD MOUNTED FOG LAMP KIT
J051162011-06-09
GENERAL
Kit Number
68913-98C
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Tools and Supplies Required
An UltraTorch UT-100 (Part No. HD-39969), Robinair Heat Gun (Part No. HD-25070) with Heatshrink Attachment (Part No. HD-41183), or other suitable radiant heating device is required for proper installation of this kit.
Electrical Contact Lubricant (Part No. 99861-02) or equivalent is required after battery cable disconnection. This item is available from a Harley-Davidson dealer.
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 refers to service manual information. A service manual for this year/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)
This kit requires up to 9 amps additional current from the electrical system.
PREPARATION
NOTE
For 2007 and later vehicles equipped with security siren:
- Verify that the Hands-Free Fob is present.
- Turn the ignition key switch to IGNITION.
For EFI Models:
WARNINGTo prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)
Follow service manual instructions to purge the fuel supply of high pressure gasoline and remove the fuel supply line.
For ALL Vehicles 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 instructions to remove the main fuse. All models except VRSC: Remove the seat. Retain all seat mounting hardware.
For ALL Vehicles With Main Circuit Breaker:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
NOTE
For 2004 and later Sportster® models, the negative battery cable is most easily disconnected at the engine crankcase.
- All models except VRSC: Refer to the service manual and follow instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. VRSC models:Refer to the service manual and follow instructions to disconnect the negative (black) battery cable from the negative (-) battery terminal.
For Carbureted Models:
WARNINGGasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a)
- Turn the fuel supply valve to OFF. Remove the fuel line from the valve.
For ALL models except VRSC:
WARNINGWhen servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
- Follow the instructions in the service manual to remove the instrument console (if equipped) from the fuel tank.
- See the correct section (Carbureted or EFI Engine) of the service manual for fuel tank removal instructions.
INSTALLATION
NOTE
WARNINGWhen routing wires and harnesses, ensure that they are clear of moving parts, heat sources and pinch points to avoid wire damage or a short circuit, which could cause loss of control resulting in death or serious injury. (00554b)
| 1. | For VRSC Models: See Figure 2. Place the wire harness from the kit into the area in front of the battery. Do not block the air intake opening. | |||||||||||||||||||||||||||||||||||||||
| 2. | For All Models Except VRSC and 2004-Later XL Models: See Figure 3. Install the wire harness from the kit. Place the relay in the opening of the frame under the seat area, and route the long leg of the harness forward along the frame backbone. | |||||||||||||||||||||||||||||||||||||||
| 3. | For 2004-Later XL Models: See Figure 4. Remove the nuts retaining the ignition module (1) and temporarily reposition the module as shown. Place the relay in the recessed area (2) of the oil reservoir. Install the ignition module. Route the long leg of the harness along the frame backbone. | 
Figure 1. Fog Lamp Schematic 
Figure 2. Install Fog Lamp Wiring harness (VRSC Models) 
Figure 3. Install Fog Lamp Wiring Harness - All Models Except VRSC (Dyna Models Shown) 
Figure 4. Install Wiring Harness (2004-Later Models) | ||||||||||||||||||||||||||||||||||||||
| 4. | For 2011 and Later Softail and 2012 and Later Dyna Models: See Figure 10. Connect the 6-place Deutsch connector (C) to the 6-place diagnostics/P&A connector on the vehicle harness. For All Other Models: See Figure 10. Cut the 6-place Deutsch connector (C) from the wiring harness (7). | |||||||||||||||||||||||||||||||||||||||
| 5. | For All 2003 and Earlier Models Except VRSC: Install a ring terminal (13) to the white power wire (F). Connect the white wire with the ring terminal to the copper stud (BAT) terminal of the main circuit breaker. For All 2004 and Later Models, Except VRSC: See SEALED SPLICE CONNECTOR section of the service manual and splice the B+ jumper harness to the white power wire (F). Connect the white wire with connector to the B+ connector on the vehicle harness. For All VRSC: Install a ring terminal (13) to the white power wire (F). Connect the white power lead to the battery positive terminal. | |||||||||||||||||||||||||||||||||||||||
| 6. | For All Models Except |
- 2011 and Later Softail:
- 2012 and Later Dyna:
- See Figure 10. Install a ring terminal (13) to the black ground wire (E) of the wiring harness. Connect the black ground wire (E) with the ring terminal to the ground stud under the seat, or at any good electrical ground point. Secure the kit harness to the adjacent harnesses with cable straps (6).
NOTE
When routing wires through the front fork, make sure the wires are clear of moving parts, to avoid pinching and possible short circuits.
| 7. | Route the forward end of the harness past the steering head, and route the lamp switch leg of the harness along the left side of the handlebar to the clutch control. | |||||||||||||||||
| 8. | Obtain the switch mounting bracket (11) from the kit. Unscrew the boot from the lamp switch, and install the switch into the bracket. Replace the boot on the switch. NOTE If the boot (12) becomes worn or damaged, or is lost, replace the boot to prevent moisture from entering the switch. | 
Figure 5. Install the Lamp Switch on the Clutch Control Clamp | ||||||||||||||||
| 9. | See Figure 5. Remove the lower screw (1) and washer from the clutch control clamp (3), and install the lamp switch and bracket assembly (2). Install the screw and washer and tighten to 7–9 N·m (60–80 in-lbs). | |||||||||||||||||
| 10. | See Figure 10. Secure the lamp switch leg of the harness to the handlebar using the wire harness retainers already on the vehicle. Snap the retainers into the holes in the handlebar. | |||||||||||||||||
| 11. | Remove the headlamp assembly following the instructions in the service manual. | |||||||||||||||||
| 12. | For VRSC models: See Figure 6. Route the unterminated wire from the switch toward the HI and LOW beam harness. For All models except VRSC: See Figure 7. Route the unterminated wire (1) from the switch through the grommet into the headlight housing. 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 toggle switch wire and pull it back through the grommet with the hooked wire. In some applications the wire from the kit harness may not fit through the headlight housing grommet. In that case, the unterminated wire must be spliced to the yellow wire outside the headlight housing. When wired as follows, the auxiliary lamps can only be operated while the main headlamp is on low beam. This conforms to many state and local laws. | 
Figure 6. HI and LOW Beam Bulb Assemblies 
Figure 7. Route Unterminated Wire 
Figure 8. Splice Fog Lamp Switch Wiring | ||||||||||||||||
| 13. | See Figure 8. Connect the unterminated wire to the low beam (yellow) wire from the headlamp socket with the sealed splice connector from the kit as follows: a. Cut the low beam (yellow) wire several inches from the headlamp connector. b. Strip 10 mm (⅜ in) of insulation from each newly cut end of the yellow wire. Strip 10 mm (⅜ in) of insulation from the cut end of the unterminated wire from the kit harness. c. Insert the ends of both yellow wires and the wire from the kit harness into the sealed butt splice connector from the kit. d. See the service manual for crimping instructions. Match the color of the connector with the color of the crimp cavity of the Crimp Tool (Part No. H-D 38125-8), and crimp the connector to the wires with the crimp tool. e. Using the UltraTorch UT-100 (H-D Part No. 39969), Robinair Heat Gun (H-D Part No. 25070), or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the meltable sealant exudes out of both ends of the connector. Let the splices cool. | |||||||||||||||||
| 14. | Install the headlamp assembly. See the service manual. | |||||||||||||||||
NOTICE When routing wires and harnesses, verify that they are clear of moving parts, heat sources and pinch points to avoid wire damage or a short circuit, which could result in electrical system damage. (00579b) | ||||||||||||||||||
| 15. | See Figure 10. Secure the wires to a suitable anchor point in the fork area (such as a harness or cable) using cable straps (6). Leave enough slack in the wires to allow the handlebar to operate freely from full left to full right. | |||||||||||||||||
| 16. | For VRSC models: Proceed to "Mounting and Connecting Fog Lamps". | |||||||||||||||||
| WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) | ||||||||||||||||||
| 17. | For All models except VRSC: Install the fuel tank. See the service manual. Proceed to "Mounting and Connecting Fog Lamps". |
Mounting and Connecting Fog Lamps
- See Figure 9. Install the fog lamps on the engine guards as shown, but do not tighten at this time.
- Route the harness along the engine guards, and secure using cable straps from the kit.
- Connect the harness wires to the fog lamps.
Return to Service
NOTE
Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the negative battery cable.
| 1. | Models with main fuse: Refer to the service manual and follow the instructions to install the main fuse. Models with main circuit breaker: a. Refer to the service manual and follow the instructions to attach the negative battery cable. b. For All models except 2004 and later XL (Sportster): Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal. | |
| 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) | ||
| 2. | For All models except VRSC: Refer to the service manual and follow instructions to install the seat. | |
| 3. | Turn the ignition key switch to "IGNITION". Check for proper fog lamp operation. Fog lamps should illuminate only while the main headlamp is on low beam. | |
| 4. | Align the fog lamps following the instructions in the service manual with the following exception: Adjust the lamps to project a beam below the headlamp beam when directed at a vertical surface such as a wall or garage door. | |
| 5. | Tighten the fog lamp clamps to 13.6 N·m (10 ft-lbs). | |
| 6. | For VRSC models: Install the right and left side covers. |
| 1 | Engine guard |
| 2 | Fog lamp (2) |
| 3 | Cable strap (12) |
| 4 | Harness |
Figure 9. Fog Lamp Mounting (rear view)
SERVICE PARTS
Figure 10. Service Parts: Fog Lamp Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Fog lamp assembly (2) | 68917-98 |
2 |
| 68199-00 |
3 |
| 68918-98 |
4 |
| 94593-98 |
5 | Connector, sealed splice | 70586-93 |
6 | Cable strap, 5.5 inches (12) (not shown) | 10065 |
7 | Wiring harness assembly | 69154-04A |
8 | Relay, power 12V 30A | 71778-98 |
9 | Fuse, blade-type 15A | 71779-98 |
10 | Switch, push button | 70370-00 |
11 | Bracket, switch mount | Not Sold Separately |
12 | Boot switch | 67880-94 |
13 | Ring terminal (2) | 9858 |
14 | B+ jumper harness | 69200013 |
Items mentioned in text, but not included in kit: | ||
A | Auxiliary/Fog lamp connectors | |
B | Relay connector | |
C | 6-place Deutsch connector | |
D | Unterminated wire | |
E | Black ground wire | |
F | White power wire | |