LIGHTED PASSENGER FOOTBOARD COVER

J052212010-07-15

GENERAL

Kit Number

50541-03A

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 and installation of additional parts or accessories may be required for proper installation of this kit on your 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 your model.

WARNING

Rider 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 this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.

Installation Requirements

2014-2016 Touring Models: Separate purchase of harness extension (Part No. 69200722) is required to locate the accessory circuit connector.

2017 and Later Touring Models: Separate purchase of harness extension (Part No. 69201599) is required to locate the accessory circuit connector.

Kit Contents

See Figure 13 and Table 1

REMOVAL

For ALL vehicles with main fuse:

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

NOTE

For vehicles equipped with security siren:

Verify that the Hands-Free Fob is present.
Turn the ignition key switch to IGNITION.

Refer to the service manual and follow the instructions to remove the main fuse.

For ALL vehicles with main circuit breaker:

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

1.	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.
2.	Remove the passenger footboard and support assemblies: a. 1992 and Earlier Models and Accessory Footboards: See Figure 1. Remove each passenger footboard and support assembly (1) from the mounting studs on the motorcycle. Depending on the type of footboard support, this will require either removal of self-locking nut (2) and bolt (3), or removal of a bolt (3) and lock washer (4) from the footboard support split hubs. Save all hardware for installation. b. 1993 and Later Touring Models: See Figure 2. Remove each passenger footboard and support assembly (1) from the mounting studs on the motorcycle. This will require removing the socket-head screw (2) and lockwasher (3) from the footboard supports. Save all hardware for installation.
3.	See Figure 1 and Figure 2. Remove any covers that may be already installed on the footboards.

ASSEMBLY

See Figure 3. Assemble the light assembly (1) into each cover (2), and place the light and cover assembly over the bottom of each footboard (3). Mark the location of the mounting holes.

Remove the light and cover assembly from the footboards. Use a center punch to make a small indentation in the exact center of each mounting hole position; this will prevent the drill bit from "walking" during use in the next step.

NOTE

When drilling cover mounting holes in the footboard, take care not to exceed a drilling depth of 12 mm (½ in) to avoid drilling through the footboard pad.

Secure the footboards in preparation for drilling the mounting holes. Using a 5/32 in. diameter drill bit, drill a hole into the footboard at each center punch point. Be careful to avoid drilling too deeply, which could damage the footboard pad; however, hole must be deep enough to allow the self-tapping screws from the kit to be installed without "bottoming" in the holes. Use a drill stop tool to limit the drilling depth to 12 mm (½ in).

See Figure 4. If present, remove the extra material (1) from the rubber bumpers (2) that protrude from the footboard castings (3) using a knife or cutting pliers.

See Figure 3. Apply lightweight oil to the threads of the four self-tapping screws (4) provided in the kit. Install the screws part way into the two drilled holes in each footboard (3); this will start to form threads in the footboard. Remove the screws, cleaning out any loose material from the holes, and clean any oil remaining on the footboards.

NOTE

See Figure 5. Alignment of the gasket is important for proper sealing of the light assembly to the Touring model stock footboard (1). This is especially critical when installing the light and cover assembly on accessory footboards (2).

See Figure 3. Place the gasket (5) on each footboard, but do not remove the backing until alignment is verified. Place the light assembly (1) on each footboard (3), and check the alignment of the gasket and light assembly. The gasket should be flush with the light assembly all the way around the light. If needed, mark the correct position of the gasket.

Remove the backing from the gasket (5) and apply to each footboard (3).

Install the light assembly (1) and cover (2) on each footboard using two self-tapping screws (4) provided in the kit, fully seating each screw.

NOTE

In the following step, route the wires as shown so there is adequate clearance to the exhaust pipe.

1	Footboard and support assembly
2	Self-locking nut
3	Bolt
4	Lockwasher
5	Cover
6	Screw (2)

Figure 1. Passenger Footboard Assembly - 1992 and Earlier Models and Accessory Footboards

1	Footboard and support assembly
2	Socket head screw
3	Lockwasher
4	Cover
5	Screw (2)

Figure 2. Passenger Footboard Assembly - 1993 and Later Touring Models

1	Light assembly
2	Cover
3	Footboard
4	Self-tapping screw (4)
5	Gasket

Figure 3. Install Footboard Cover

Secure the wiring harness to the footboard support:

a. 1992 and Earlier Model Vehicles and Accessory Footboards: See Figure 6. Route the wiring harness (1) along the bottom and side of each footboard support (2) as shown. Allow a small loop (3) of slack in the harness to prevent pulling the wires when folding the footboard. Secure the harness to the footboard supports using cable straps (4).

b. 1993 and Later Touring Model Vehicles: See Figure 7. Route the wiring harness (1) along the bottom of each footboard support (2), placing the harness in the recesses whenever possible. Allow a small loop (3) of slack in each harness to prevent pulling the wires when folding the footboard. Secure the harness to the footboard supports using cable straps (4).

1	Rubber bumper extra material
2	Large rubber bumper
3	Footboard casting

Figure 4. Remove Rubber Bumper

INSTALLATION

1.	Install the footboards onto the vehicle: a. 1992 and Earlier Model Vehicles and Accessory Footboards: See Figure 8. Install each footboard and cover assembly (1) in its original position on the mounting studs, aligning the bolt hole with the machined groove in the stud. Secure each footboard using either a self-locking nut (2) and bolt (3), or removal of a bolt (3) and lock washer (4) (depending on the type of footboard support). Tighten the nut to 14 N·m (10 ft-lbs). b. 1993 and Later Touring Model Vehicles: See Figure 9. Install each footboard and cover assembly (1) on the mounting studs, aligning the bolt hole in the support with the hole in the mounting stud. Secure each footboard using a socket-head screw (2) and lockwasher (3). Tighten the allen screws to 41 N·m (30 ft-lbs).
2.	NOTE When routing wires along the frame tubes, make sure the wires are clear of moving parts, heat sources and pinch points, to avoid possible short circuits. Make sure the left footboard harness is clear of the drive belt. Route the footboard light wiring harnesses along the rear frame uprights up to the seat pan area. Secure the harnesses to the frame using cable straps as needed.

NOTE

Electrical connections will vary depending on the year and/or model of your motorcycle. Refer to the specific electrical connection instructions that apply to your motorcycle.

1	Touring model stock footboard
2	Accessory footboard

Figure 5. Footboard Identification

Electrical Connections - All 1994 and Later Touring Models

1.	See Figure 10. Install the 4-place Deutsch connector to the floorboard wiring harness. See the service manual. a. Install the terminal of the orange wire into cavity 3 of the connector. b. Install the terminal of the black (ground) wire into cavity 4 of the connector. c. Install seal pins in cavities 1 and 2 of the connector. d. Secure terminals with the secondary lock.
2.	Plug the right (1) and left (2) light assembly wiring harnesses into the footboard wiring harness (3).
3.	Connect the footboard wiring harness connector (4) into the accessory plug located under the seat. Proceed to FINAL ASSEMBLY.

Electrical Connections - 2011 and later Softail Models

1.	See Figure 10. Install the 6-place Deutsch connector (5) to the floorboard wiring harness. See the service manual. a. Install the terminal of the orange wire into cavity 5 of the connector. b. Install the terminal of the black (ground) wire into cavity 2 of the connector. c. Install seal pins in cavities 1, 3, 4 and 6 of the connector. d. Secure terminals with the secondary lock.
2.	Plug the right (1) and left (2) light assembly wiring harnesses into the footboard wiring harness (3) supplied in the kit.
3.	Connect the footboard wiring harness connector (4) into the accessory plug located under the seat. Proceed to FINAL ASSEMBLY.

1	Wire harness
2	Footboard support
3	Loop
4	Cable straps

Figure 6. Wire Harness Routing - 1992 and Earlier Models and Accessory Footboards

1	Wire harness
2	Footboard support
3	Loop
4	Cable straps (3)

Figure 7. Wire Harness Routing - 1993 and Later Touring Models

1	Footboard and support assembly
2	Self-locking nut
3	Bolt
4	Lockwasher

Figure 8. Passenger Footboard Assembly - 1992 and Earlier Models and Accessory Footboards

1	Footboard and support assembly
2	Socket head screw
3	Lockwasher

Figure 9. Passenger Footboard Assembly - 1993 and Later Touring Models

Electrical Connections - All 1993 and Earlier Touring Models and 2010 and Earlier Softail Models Softails

1.	See Figure 11. Plug the right (1) and left (2) light assembly wiring harnesses into the footboard wiring harness (3) supplied in the kit.
2.	Cut the existing terminal from the black wires (5), as close to the connector as possible. Strip a 10 mm (⅜ in) section of insulation from the end of each wire to be spliced, and install a ring terminal (6) supplied in the kit.
3.	Connect the ring terminal (6) to a ground stud located under the seat.
4.	NOTE See Splicing Information (All 1993 and Earlier Models and All Softails) for detailed usage information for sealed-splice connectors. Cut the existing terminal from the orange wires (7) and install a pre-insulated, seal splice connector (8) supplied in the kit. Splice the other end of the connector into an accessory wiring circuit (9) on the main harness near the rear lighting connector under the seat (orange or orange/white wire). Proceed to FINAL ASSEMBLY.

Splicing Information (All 1993 and Earlier Touring Models and 2010 and Earlier Softail Models)

1.	Cut the terminals off the wires as close to the terminals as possible.
2.	Strip a 10 mm (⅜ in) section of insulation from the end of each wire to be spliced.
3.	See Figure 12. For each splice, insert the wire ends into the splice connector as shown.
4.	Match the color of the butt splice connector with the color of the crimp cavity of the crimping tool. Using an Crimping Tool (H-D 38125-8), crimp the wires into the connector.

Using UltraTorch UT-100 (H-D 39969), Robinair Heat Gun (H-D 25070) with heatshrink Attachment (H-D 41183), or other suitable radiant heating device, heat the crimped splice to encapsulate the butt spice connector. Apply heat from the center of the crimp out to each end until the meltable sealant exudes out of both ends of the connector.

FINAL ASSEMBLY

1.	See the service manual and connect the battery negative (-) cable or install the main fuse.
2.	See service manual. Install seat. After installing seat, pull up on the seat to verify that it is secure.

1	Right light assembly harness
2	Left light assembly harness
3	Footboard wiring harness
4	4-way connector - 1994 and later Touring models
5	6-way connector - 2011 and later Softail models
6	Terminal (2)

Figure 10. Electrical Connections - All 1994 and Later Models

1	Right light assembly harness
2	Left light assembly harness
3	Footboard wiring harness
4	Terminal (2)
5	Black wire (ground)
6	Ring terminal
7	Orange wire
8	Sealed splice connector
9	Accessory circuit wire (orange or orange/white)

Figure 11. Electrical Connections - All 1993 and Earlier and 2010 and Earlier Softail Models

1	Stripped wire ends inserted into connector
2	Wire ends crimped in connector
3	Connector after heat has been applied

Figure 12. Sealed Splice Connections

SERVICE PARTS

Figure 13. Service Parts: Lighted Passenger Footboard Covers

Table 1. Service Parts Table

Item	Description (Quantity)	Part Number
1	Footboard cover assembly (2)	50567-03
2	Light assembly (2), includes gasket (item 13)	50548-03
	Kit, hardware installation (includes items 3 through 12)	50568-03A
3	Harness, footboard	69200098
4	Screw, self-tapping, #10 (4)	Not Sold Separately
5	Ring terminal, 1/4 in ID (2)	9858
6	Cable strap (8)	10181
7	Splice connector (2)	70586-93
8	Housing, 4-way socket, black	72114-94BK
9	Housing, 6-way socket, black	72116-94BK
10	Secondary lock, 4-way socket	72154-94
11	Secondary lock, 6-way socket	72156-94
12	Seal pin (4)	72195-94
13	Gasket (2)	Not Sold Separately