HORN COVER KIT
J059632021-08-02
GENERAL
Kit Number
68189-07A , 69039-09A , 69166-01B , 69167-02B , 61300452 , 61300621 , 61300622 , 61300623 , 61301045 , 61301177
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
ELECTRICAL OVERLOAD
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)
Additional Requirements
Separate purchase of LOCTITE® 271 MEDIUM STRENGTH THREADLOCKER AND SEALANT (Red) (part no. 99671-97) or equivalent is required for proper installation of this kit.
PREPARE
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
| 1. | Remove main fuse. See service manual. |
REMOVE
| 1. | Remove acorn nut (1) and flat washer (2) to free horn assembly from rubber mount stud (C). | |
| 2. | Disconnect elbow terminals from spade contacts and release main harness conduit from J-clamp (E). | |
| 3. | Remove flange nut (F) from circular recess at back of horn bracket. Remove horn from chrome horn cover (5). | |
| 4. | Remove flange screws (D). | |
| 5. | Remove and retain speed nuts (4) from horn cover unless provided in kit. |
INSTALL
| 1. | Clip speed nuts (4) to horn bracket (5) at top and bottom holes. | |
| 2. | Install supplied washer (6) in kit onto horn stud. | |
| 3. | Fit horn into new horn cover so the stud at back slides through hole in horn bracket. | |
| 4. | Apply two drops of Loctite® 271 (Red) to threads of nut (F) fastening the horn to the horn cover. | |
| 5. | NOTE Over tightening the flange nut (F) can cause permanent horn damage resulting in reduced volume and tone quality. Torque: 9–11.3 N·m (80–100 in-lbs) Horn stud nut | |
| 6. | Install flange screws. a. All kits except 61301177: Install flange screws (D). b. Kit 61301177: Install flange screws (D, 7). c. Tighten flange screws (D, 7). Torque: 4–4.5 N·m (35–40 in-lbs) | |
| 7. | NOTE The horn is not polarity sensitive. Elbow terminals can connect to either spade or contact. | |
| 8. | Capture main harness conduit in J-clamp. Install horn bracket onto rubber mount stud. | |
| 9. | Apply 2 drops of Loctite 271 (Red) to threads on horn, rubber mount stud (C). | |
| 10. | Install flat washer (2) and acorn nut (1). | |
| 11. | Tighten acorn nut. Torque: 9–11.3 N·m (80–100 in-lbs) Horn mount acorn nut |
COMPLETE
| 1. | Install main fuse. See service manual. | |
| 2. | Test horn. |
SERVICE PARTS
Figure 1. HORN COVER KIT (Cover shown may not reflect actual cover in kit.)
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Nut, acorn (For kit 61300452 ) | 10400023 |
2 | Washer (For kit 61300452 ) | 10600030 |
3 | Horn bracket, black (For kit 61300452 ) | 69274-10 |
Horn bracket, chrome (For kit 68189-07A ) | Not Sold Seperately | |
4 | Speed nuts, (2) (For kit 61300452 ) | 8108 |
5 | Horn cover assembly (For kit 61300452 only). | 61300477 |
Horn cover assembly (For kits 68189-07 , 69039-09A , 69166-01B , 69167-02B , 61300621 , 61300622 , 61300623 , 61301045 , 61301177 | Not Sold Seperately | |
6 | Washer (1) (For kits 61300452 , 68189-07A , 69039-09A , 69166-01B , 69167-02B , 61300621 , 61300622 , 61300623 , 61301045 , 61301177 ) | 10300085 |
7 | Screw, flange (1) (For kit 61301177 ) | 3588 |
Items mentioned in text, but not included in kit: | ||
A | Horn mount bracket assembly | |
B | Horn, trumpet | |
C | Horn, rubber mount | |
D | Screw, large flange | |
E | Clamp | |
F | Hex nut, (metric, M6) | |