POLICE EMERGENCY LAMP KIT
J058962013-06-17
GENERAL
Kit Number
41000203
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 vehicle is sold for non-police use. Follow all applicable federal, state and local regulations when changing to a civilian vehicle.
Installation Requirements
Models with turn signals mounted on the upper or lower fork
clamp require separate purchase of a Front Directional Relocation Kit (Part No. 68603-01).
A Packard Crimping Tool (Part No. HD-38125-8) or equivalent device is required for proper installation of this kit.
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.
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 and a Police Model service manual supplement for this year/model motorcycle is required for this installation. One 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 2.8 amps more current from the electrical system.
PREPARATION
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)
Purge and disconnect fuel supply line.
WARNINGTo 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: With security fob present, turn ignition switch ON. After system is disarmed, turn ignition switch OFF. IMMEDIATELY remove the main fuse per the service manual.
- For vehicles WITHOUT security siren: See the service manual to remove the main fuse or disconnect the battery cables.
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)
- Vehicles with instrument console on tank: See the service manual to remove the instrument console from the fuel tank.
- See the service manual for fuel tank removal instructions.
INSTALLATION
| 1. | See Figure 1. Install the right side mounting bracket (2) on the fork tube (1) using the right side clamp (3) and two hex socket head screws (4-5). Tighten the outboard screw (4) to 8–9 N·m (70–80 in-lbs). Tighten the inboard screw (5) to 8–9 N·m (70–80 in-lbs). | |||||||||||||||||||||||||
| 2. | See Figure 2. Route the wire (2) of the blue lamp (1) through the mounting bracket (3). Secure the lamp to the bracket with a clamp block (4), lockwasher (5) and retainer (6). Tighten the retainer to 22–24 N·m (16–18 ft-lbs). | |||||||||||||||||||||||||
| 3. | Slide the conduit (7) over the lamp wire. | |||||||||||||||||||||||||
| 4. | Repeat Steps 1-3 on the left side of the vehicle using the red lamp. | |||||||||||||||||||||||||
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) | ||||||||||||||||||||||||||
| 5. | See Figure 5. Install the wiring harness (18). Place the flasher (20) in the opening beneath the fuel tank, and route the long leg of the harness forward along the frame backbone inside the plastic wire caddy. NOTE Electrical connectors are identified in the service manual by the numbers and letters shown here within brackets. | |||||||||||||||||||||||||
| 6. | Route the terminated black wire (C) to the P&A diagnostic port [C91A]. Insert the black wire terminal into cavity 6 of the gray six-way socket housing (21) from the kit. | |||||||||||||||||||||||||
| 7. | Plug the gray socket housing into the P&A diagnostic port. Secure the connectors and wire with cable straps (15) from the kit. | |||||||||||||||||||||||||
| 8. | Route the harness past the steering head. Route the lamp switch (A) leg of the harness along the left side of the handlebar to the clutch control. | |||||||||||||||||||||||||
| 9. | Unscrew the boot (19) from the lamp switch. Install the switch into the switch mounting bracket (12). Install the boot on the switch. NOTE Over time the boot may become lost, worn or damaged. Replace the boot to prevent moisture from entering the switch. | 
Figure 1. Install Mounting Bracket on Fork Tube (Right Side Shown) 
Figure 2. Install Lamp (Right Side Shown) | ||||||||||||||||||||||||
| 10. | See Figure 3. Remove the lower screw (1) and washer from the clutch control clamp. Install the lamp switch and bracket assembly (2) with the screw and washer. Tighten to 7–9 N·m (60–80 in-lbs). | |||||||||||||||||||||||||
| 11. | Secure the lamp switch leg of the harness to the handlebar with the new wire harness retainers ( Figure 5 , Item 17) as needed. Snap the retainers into the holes in the handlebar. | |||||||||||||||||||||||||
| 12. | Get a piece of heat shrink tube (13) and a sealed splice connector (14) from the kit. See Figure 4. Slide the heat shrink tubing (1) over the blue wire (2) of the kit harness. Crimp the sealed splice connector (3) to the wire using a Packard Crimping Tool (Part No. HD-38125-8) or equivalent. | |||||||||||||||||||||||||
| 13. | Bring the right side lamp wire (4) to the connector. Trim the wire, allowing approximately 25 mm (1 in) of the wire to extend past the sealed splice connector. Trim the conduit (5) approximately 38 mm (1.5 in) back from the end of the wire. | |||||||||||||||||||||||||
| 14. | Remove approximately 10 mm (0.38 in) of insulation from the end of the lamp wire. | |||||||||||||||||||||||||
| 15. | Insert the end of the lamp wire into the sealed splice connector. Crimp the wire to the connector with the Packard Crimping Tool. | 
Figure 3. Install Lamp Switch on Clutch Control Clamp 
Figure 4. Connect Lamp Wires to New Harness | ||||||||||||||||||||||||
| 16. | Repeat steps 12-15 to connect the left side lamp wire (7) to the red wire (6) of the harness. |
Installation of protective shrink tubing over wire leads is necessary in the installation of this kit to the motorcycle.
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 connectors and tubing on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
NOTE
Protect the heat shrink tubing from the heat source while applying heat to the sealed splice connectors.
- Use a heat gun or suitable radiant-heating device to shrink the tubing and conduit to the connectors.
- Slide the heat shrink tubing (1) away from the splice. Use the radiant heating device to heat the crimped sealed splice connectors (3). 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 connector cool.
- Slide the heat shrink tubing (1) over the splice. Use the radiant heating device, heat the heat shrink tubing to encapsulate the sealed splice connection. Apply heat from the center of the crimp out to each end.
- See Figure 5. Secure the wires to the lower fork steering bracket using adhesive backed clips (16) from the kit.
COMPLETION
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)
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)
| 1. | See the service manual for fuel tank installation instructions. NOTE Verify that the ignition key switch is in the OFF position before installing the main fuse. | |
| 2. | See the service manual to install the main fuse. | |
| 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) | ||
| 3. | See the service manual to install the seat. NOTE Properly aligned police emergency lamps shine straight ahead, with the center of the light beams even with a horizontal line drawn on a wall 7.6 m (25 ft) away. Draw the line on the wall at the same height as the center of the lamps with the rider mounted on the vehicle. | |
| 4. | Align the lamps. a. Insert a flare nut socket at the bottom of the turn signal mounting bracket. Loosen the locknut on the stud. b. Move the lamp and swivel block to the desired position. c. Tighten the locknut to 24.4 N·m (18 ft-lbs). |
OPERATION
Set the engine hot idle to 1000 rpm for best operation.
SERVICE PARTS
Figure 5. Service Parts, Police Emergency Lamp Kit
SERVICE PARTS
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Mounting bracket, police emergency lamp (right) | 68302-00 |
2 | Mounting bracket, police emergency lamp (left) | 68303-00 |
3 | Clamp, police emergency lamp mounting bracket (right) | 68304-00 |
4 | Clamp, police emergency lamp mounting bracket (left) | 68305-00 |
5 | Screw, hex socket button head, 1/4-20 x 19 mm (0.75 in) long, with lock patch (4) | 927A |
6 | Pursuit lamp assembly (chrome), right side (with blue lens) | 69288-03A |
7 | Pursuit lamp assembly (chrome), left side (with red lens) | 68779-03A |
8 | Clamp block (2) | 68720-62 |
9 | Lockwasher, internal tooth (2) | 7130W |
10 | Retainer, pursuit lamp (2) | 68306-00 |
11 | Conduit, extruded vinyl, 0.76 m (30 in) long (2) | 70530-89 |
12 | Bracket, push button switch mounting | 70371-00 |
13 | Shrink tube (2) | 72266-94 |
14 | Sealed splice connector, blue (2) | 70586-93 |
15 | Cable strap (12) | 10181 |
16 | Clip, adhesive backed (4) | 10102 |
17 | Wire harness retainer (4) | 70345-84 |
18 | Pursuit lamp wire harness (includes items 19-21) | 69200913 |
19 |
| 67880-94 |
20 |
| 68563-04A |
21 |
| 72136-94GY |
Items mentioned in text, but not included in
kit: | ||
A | Push button switch | |
B | Relay terminal connector | |
C | Terminated black wire | |