CHROME FLAMES TURN SIGNAL KITS
J052062010-07-02
GENERAL
Kit Numbers
69844-08A, 69845-08A, 69945-08A, 69960-08A
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase of additional parts or accessories may also be required for proper installation of a Turn Signal Kit on a specific model motorcycle. See the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for a specific model.
The housings for these turn signals are designed for side
mounting only. If the front turn signals on a specific vehicle mount from the top, they will require relocation to accommodate this installation.
Several different kits are available for side mounting of the front turn signals. See the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for the relocation kit or kits that fit a specific year and model motorcycle.
Tools and Supplies Required
Electrical Contact Lube (Part No. 99861-02) or equivalent is required after battery cable disconnection. This item is available from a Harley-Davidson dealer.
2011 and later Softail FLSTF and FLSTFB models will require use of an UltraTorch UT-100 (HD-39969), Robinair Heat Gun (HD-25070) with Heatshrink Attachment (HD-41183), or other suitable radiant heating device.
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.
PREPARATION
NOTE
For vehicles equipped with security siren:
- Verify that the Hands-Free Fob is present.
- Turn the ignition key switch to IGNITION.
For EFI models EXCEPT VRSC:
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 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 the instructions to remove the main fuse. Remove and retain the seat and all mounting hardware.
For 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)
- Refer to the service manual and follow the instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
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)
- Loosen the fuel tank. See the correct section (Carbureted or EFI Engine) of the service manual for instructions.
FRONT TURN SIGNAL LAMP REMOVAL
NOTE
Cover the front fender with an H-D Service Cover or clean shop towel to prevent scratching the finish.
Models With Fork-Mounted Turn Signals
No front turn signal relocation kit should be required.
- Separate the turn signal connector halves under the fuel tank.
- Make note of the wire colors and positions in each cavity of the Multilock socket housing leading from the turn signals. Refer to the wiring diagram and the Tyco/AMP MULTILOCK ELECTRICAL CONNECTORS section in the service manual. Remove the terminals from only the socket housing. DO NOT remove the terminals from the pin housing leading from the vehicle harness.
- Make note of the turn signal wire routing, and the location of cable straps that must be replaced. Remove the front turn signals from the turn signal clamps or stalks. Retain the clamps or stalks and all mounting hardware. The lamps may be discarded.
Models With Handlebar-Mounted Turn Signals EXCEPT 2011 and Later FLSTF and FLSTFB
Refer to the instructions that come with the Front Turn Signal Relocation Kit to perform the following:
- Separate the turn signal connector halves under the fuel tank.
- Make note of the wire colors and positions in each cavity of the Multilock socket housing leading from the turn signals. Refer to the wiring diagram and the correct section in the service manual appendix. Remove the terminals from only the socket housing. DO NOT remove the terminals from the pin housing leading from the vehicle harness.
- Remove and discard the original equipment front turn signals from the vehicle handlebars.
2011 And Later FLSTF and FLSTFB Models With Handlebar-Mounted Turn Signals
Installation of protective shrink tubing over wire leads is necessary in the installation of the Flame Turn Signals to the motorcycle.
- See Figure 1. Cut the turn signal wires and conduit flush with the grommet (1) on the underside of the handlebar lower switch housing (2).
- Separate the upper (3) and lower switch housings per service manual instructions.
- Remove the grommet from the end of the turn signal wire vinyl conduit (4) still connected to the switch housing.
- Make about a 25 mm (1 in) long slit in the end of the conduit. Cut one wire back about 12 mm (½ in) from the end of the conduit. Cut the second wire back about 6 mm (¼ in) from the end of the conduit.
- Slip the 50.8 mm (2 in) long section of encapsulating (dual wall) shrink tube (5) over the conduit and wires.
WARNINGBe sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
- Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the tubing on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
- Use a heat gun or suitable radiant-heating device to shrink the tubing to the wires and conduit.
- Assemble the switches and switch housings to the handlebar per service manual instructions, tucking the shrink-sealed wire ends back inside the switch housings. Repeat on the opposite side of the vehicle.
| 1 | Grommet |
| 2 | Handlebar lower switch housing |
| 3 | Handlebar upper switch housing |
| 4 | Turn signal wire vinyl conduit |
| 5 | Shrink tube |
Figure 1. Cut Turn Signal From Switch Assembly
NEW FRONT TURN SIGNAL LAMP INSTALLATION
NOTE
Some earlier front turn signal relocation kits called for butt-splicing of the turn signal wires. This should not be necessary for this kit. Follow the steps below to connect the new turn signal wires into the turn signal connectors.
| 1. | ALL models: See Figure 2. Obtain the new left- and right-front turn signal lamps (Items 3 and 4) from the kit. The front lamps can be identified by the "D"-shaped mounting boss (D) on the housing. Identify left and right lamps by the visor and raised flames at the top. | |
| 2. | Models that HAD handlebar-mounted turn signals installed: Refer to the instructions that came with the Front Turn Signal Relocation Kit to install the new right- and left-front turn signal lamps. Models that HAD fork-mounted turn signals installed: install the new right- and left-front turn signal lamps to the front forks using the clamps or stalks and mounting hardware removed earlier. ALL models: Align the lamp housings so that the lenses will be aimed straight ahead for proper visibility. While holding each turn signal in position, tighten per the instructions in the Front Turn Signal Relocation Kit. | |
| 3. | Route the turn signal wiring to the area under the fuel tank per the notes made earlier or the instructions in the relocation kit. | |
| 4. | Obtain six socket terminals (1) from this kit. Refer to the service manual appendix, and follow the instructions to crimp the socket terminals to the new turn signal wire leads. Install each terminal into the correct cavity of the socket housing per the notes made earlier. For 2011 and later FLSTF and FLSTFB models: Note that the right-side lamp violet wire gets installed into the cavity that mates with a blue/orange wire. The left-side lamp violet wire gets installed into the cavity that mates with a blue/pink wire. For ALL other models: Note that the right-side lamp violet wire gets installed into the cavity that (in most cases) originally contained a brown wire. | |
| 5. | Connect the socket housing to the main harness pin housing under the fuel tank. Install cable straps (2) from the kit as needed to retain the turn signal wiring. | |
| 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) | ||
| 6. | Install the fuel tank per service manual instructions. Proceed to Rear Turn Signal Lamp Removal for the specific model motorcycle. |
REAR TURN SIGNAL LAMP REMOVAL
VRSC Models
Refer to the instructions that come with the Rear Turn Signal Mounting Kit. to remove and discard the original equipment rear turn signal lamps and supports from the license plate bracket.
All Models Except VRSC
- See the service manual for rear turn signal LAMP HOUSING REPLACEMENT instructions for the specific model motorcycle. Remove the center tail/stop lamp lens and bulb assembly. Press the latches on the left-side and right-side two-place turn signal socket housings, and disconnect the socket housings from the center lamp circuit board.
- Remove the turn signal wires from the retention clips under the fender.
- Make note of the wire colors and positions in each cavity of the turn signal socket housings. Refer to the wiring diagram and the correct section in the service manual appendix. Remove the terminals from the socket housings.
- Remove the fasteners retaining the turn signal lamps and supports from the underside of the fender.
- Pull the old turn signal lamp wires and terminals through the hole in the fender to free the original lamps from the motorcycle. Separate the lamps from the supports, and set the supports and mounting hardware aside for reassembly. The lamps may be discarded.
NEW REAR TURN SIGNAL LAMP INSTALLATION
VRSC Models
- Get the components from the the Rear Turn Signal Mounting Kit, and the new left- and right-rear turn signal lamps (Items 7 and 8) and four socket terminals (1) from this kit. The rear lamps can be identified by the round mounting boss in a teardrop-shaped depression (E) in the housing. Identify left and right lamps by the visor and raised flames at the top.
- Refer to the instructions in the Rear Turn Signal Mounting Kit. to install the new rear turn signal lamps and supports to the license plate bracket. Align the lamp housings so that the lenses will be aimed straight rearward for proper visibility. While holding each turn signal in position, tighten the fasteners securely.
- Proceed to Final Assembly.
All Models Except VRSC
| 1. | Get the new left- and right-rear turn signal lamps (Items 7 and 8) from the kit. The rear lamps can be identified by the round mounting boss in a teardrop-shaped depression (E) in the housing. Identify left and right lamps by the visor and raised flames at the top. | |
| 2. | See the service manual for rear turn signal LAMP HOUSING REPLACEMENT instructions for the specific model motorcycle. Feed the turn signal wires through the lamp supports removed earlier, and into the holes in the fender. | |
| 3. | Attach the turn signal lamps and supports to the vehicle with the fasteners removed earlier. Align the lamp housings so that the lenses will be aimed straight rearward for proper visibility. While holding each turn signal in position, tighten the fasteners to 10.8–13.6 N·m (96–120 in-lbs) | |
| 4. | Route the turn signal wires to the tail/stop lamp, and feed the four turn signal wires out through the opening in the lower left of the tail/stop lamp base. At the wire ends, verify which wires come from the left or right turn signal. | |
| 5. | Cut any excess length from the turn signal wires, leaving enough wire to easily affix the new terminals and insert the turn signal connectors into the tail lamp circuit board. | |
| 6. | Obtain the four socket terminals (1) from this kit. Refer to the service manual appendix, and follow the instructions to crimp the socket terminals to the new turn signal wire leads. NOTE Be sure to keep the wire pair from each turn signal properly identified through the following steps. On XL models, the white connector is used for the left-side turn signal. If necessary, carefully strip a short length of the shrink conduit from the ends of the wire pairs for ease of assembly to the connectors. Take care not to cut the wire insulation. | |
| 7. | For each turn signal, insert the violet wire into cavity 1 of the two-place turn signal connector. Insert the black wire into cavity 2 of the connector. | |
| 8. | Insert the left-side and right-side two-place turn signal connectors into the correct cavities in the tail lamp circuit board. | |
| 9. | Position the turn-signal wires so they will not be pinched during tail/ stop lamp installation. Install the tail/ stop lamp lens to the lamp base with the two screws removed earlier. Tighten to 2.3–2.7 N·m (20–24 in-lbs) | |
| 10. | Insert the turn signal wires into the retention clips under the fender. | |
| 11. | Proceed to Final Assembly. |
FINAL ASSEMBLY
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: Refer to the service manual and follow the instructions to attach the negative battery cable. 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. NOTE Check for proper lamp operation before riding the motorcycle. Weak, intermittent, or non-operational lamps indicate a poor connection or a short in the wires. If the rear turn signals operate opposite of switch function, remove the tail lamp lens assembly and disconnect and reverse the turn signal electrical connectors in the tail lamp assembly. Test the rear turn signals again for proper function. | |
| 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) | ||
| 2. | Turn the ignition key switch to ON to power the lamps, but do not start the motorcycle. Make sure that both turn signals, the tail/stop lamp assembly and the license plate lamp function properly. |
SERVICE PARTS
Table 1. Service Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Common items for ALL kits | 1 | Socket terminal (10) | 73191-96 |
2 | Cable strap (6) | 10181 | |
3 | Shrink tube, encapsulating (dual wall), 50.8 mm (2 in) long (2) | 72411-97 | |
4 | Socket housing, six-way | 73156-96BK | |
Kit 69844-08A Chrome Flames, Amber lens, Domestic additional contents | 5 | Turn signal assembly, front (left) | 69891-08 |
6 | Turn signal assembly, front (right) | 69890-08 | |
7 | Turn signal assembly, rear (left) | 69893-08 | |
8 | Turn signal assembly, rear (right) | 69892-08 | |
Kit 69845-08A Chrome Flames, Amber lens, HDI additional contents | 5 | Turn signal assembly, front (left) | 69887-08 |
6 | Turn signal assembly, front (right) | 69886-08 | |
7 | Turn signal assembly, rear (left) | 69889-08 | |
8 | Turn signal assembly, rear (right) | 69888-08 | |
Kit 69945-08A Chrome Flames, Smoked lens, Domestic additional contents | 5 | Turn signal assembly, front (left) | 69957-08 |
6 | Turn signal assembly, front (right) | 69956-08 | |
7 | Turn signal assembly, rear (left) | 69959-08 | |
8 | Turn signal assembly, rear (right) | 69958-08 | |
Kit 69960-08A Chrome Flames, Smoked lens, HDI additional contents | 5 | Turn signal assembly, front (left) | 69947-08 |
6 | Turn signal assembly, front (right) | 69946-08 | |
7 | Turn signal assembly, rear (left) | 69949-08 | |
8 | Turn signal assembly, rear (right) | 69948-08 | |
Additional service parts available: | |||
A | Bulb (clear), S-8, dual contact (domestic) Bulb (clear), S-8 (E-approved), single contact (HDI) Bulb (amber), S-8, dual contact (domestic) Bulb (amber), S-8 (E-approved), single contact (HDI) | 68168-89A 68163-84 69331-02 69348-03 | |
B | Lens (amber) Lens (smoked) | 69022-03 69206-03 | |
C | Bulb (clear), S-8, single contact (domestic) Bulb (clear), S-8 (E-approved), single contact (HDI) Bulb (amber), S-8, single contact (domestic) Bulb (amber), S-8 (E-approved), single contact (HDI) | 68572-64B 68163-84 69330-02 69348-03 | |
Items mentioned in text, but not included in kit: | |||
D | "D"-shaped mounting boss on front lamp housing (left side shown) | ||
E | Round mounting boss in teardrop-shaped depression in rear lamp housing (left side shown) | ||
Figure 2. Service Parts, Turn Signal Kits