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AUXILIARY POWER STATION
J061182014-10-01
GENERAL
It is advised that this kit is installed by an authorized Harley-Davidson dealer.
Kit Number
69201087, 69201102
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 your model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Installation Requirements
69201102 Kits: A separate purchase of harness Electrical Connector (H-D Part No. 69200722) is required to connect the accessory circuit connector.
Electrical Overload
WARNING
Rider and passenger safety depend upon the correct installation of this kit. 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. (00308b)
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)
Kit Contents
See Figure 7 and Table 1.
Installation
Vehicle Preparation
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Remove main fuse. See the service manual.
  2. Remove fuel tank. See the service manual.
  3. Remove seat. See the service manual.
  4. Remove outer fairing. See service manual.
USB Hub Installation FLH Models:
1. See Figure 1. Remove USB cable (4) from HSD connection (3) on back of radio.
1Accessory power [299]
2Storage/media compartment
3HSD connection
4USB cable, storage/media compartment
Figure 1. USB Hub Wiring Locations
2. See Figure 2. Install power cable (3) to accessory power [299] (1, Figure 1 ).
1USB hub
2USB cable
3Power cable
4HSD cable
5HSD outlet
6Adhesive tape (not shown)
Figure 2. USB Hub Wiring Diagram
3. Install HSD cable (4, Figure 2 ) to HSD connection (3, Figure 1 ).
4. Install USB cable (4, Figure 1 ) to HSD port (5, Figure 2 ).
5. Position USB hub (2, Figure 3 ) so it is on the edge of the storage/media compartment (4). As shown. Clean mounting surface with 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry completely. Remove paper backing from adhesive tape (3). Press and hold firmly to secure USB hub.
6. Route the USB cable (2, Figure 2 ) along the tray along the frame and over fender into the Tour-Pak or saddlebag. Secure as needed with cable straps.
1Storage/media compartment
2USB hub
3Adheasive tape
4Edge of storage/media compartment
Figure 3. USB Hub Installation
7. Follow the steps for Tour-Pak Port Installation or Saddlebag Port Installation in this document to complete installation.
USB Hub Installation FLT Models:
1. See Figure 1. Remove USB cable (4) from HSD connection (3) on back of radio.
2. See Figure 4. Install USB cable (4) from media/storage and connect to USB hub (1) as shown.
3. Install HSD cable (3) to radio.
4. Install power cable (6) to power cable (7) [299].
5. Route USB cable (5) to rear of motorcycle.
6. Clean mounting surface with 50-70% isopropyl alcohol and 30-50% distilled water. Allow to dry completely.
1USB hub
2Bracket
3HSD cable to radio
4USB cable from storage/media compartment
5USB cable to Tour-Pak/saddlebag
6Power cable
7Power cable [299]
Figure 4. USB Hub Installation and Cable Location
7. Follow the steps for Tour-Pak Port Installation or Saddlebag Port Installation in this document to complete installation.
Tour-Pak USB/Power Port Installation
1. Remove Tour-Pak bottom or liner, if equipped.
2. Complete the routing of USB cable (2, Figure 2 ) following the routing of the existing power port wire.
3. See Figure 5. Remove screws (3) and power port, if equipped.
4. Install bracket (7) to USB/power port (6) [299] securing with screws (1) as shown.
5. Install bracket (2) securing with screws (3). Tighten screws to 2.8–4 N·m (25–35 in-lbs).
6. Mate Accessory cable (4) and USB cable (5) to USB/power port.
7. Trim Tour-Pak bottom or liner, if equipped.
8. Install USB cable and power cable into USB/power port. Power cable [258] may be under mounting plate or liner.
9. Coil extra cable. Secure with cable straps.
10. Install Tour-Pak bottom or liner.
11. Install USB/power port to bracket (2) securing with screw (8). Tighten screws to 2.2–2.8 N·m (20–25 in-lbs).
1Screw, self tapping (2)
2Bracket, tour-pak, USB and power outlet
3Screws, existing (2)
4Accessory power cable, existing [258]
5USB cable
6USB/power port
7Bracket, USB and power outlet
8Screw, button head
Figure 5. USB/12Volt Port, Tour-Pak
Saddlebag USB/Power Port Installation
1. Install Electrical Connector (H-D Part No. 69200722, 71400105 or 71400106). Follow the instructions for those kits.
2. Remove all items from saddlebag.
NOTE
Check the following before choosing a mounting spot for the power port:
  • Place connectors where they can be easily accessed for saddlebag removal.
  • Do not mount the power port housing and bracket on a rib or complex curved surface inside the saddlebag.
  • Select a position for the power port harness to pass through the inboard wall of the saddlebag. Recommended position is as high and as far forward as possible.
  • Make sure that the power port harness connector will easily reach the mating charger harness connector after passing through the saddlebag wall.
  • The power port can point in any orientation vertical, horizontal or any angle. Allow room in front of the power port to install the mating connector of any anticipated electronic devices that are used.
  • Check position of the screw heads and wire pass-through for clearance to all moving components.
3. Select a flat surface inside the saddlebag, on the inboard wall.
4. Using the bracket (5) as a template, mark the locations for the two mounting holes. Mark the location for the power port pass-through opening with a center punch.
5. See Figure 6. Install bracket (5) to USB/power port (8) securing with screws (1).
6. Drill two 9.5 mm (0.38 in) holes for mounting the power port. Drill a 16 mm (0.62 in) hole in the power port harness pass-through location.
7. Install rubber grommets (4) into each of the 9.5 mm (0.38 in) power port mounting holes drilled in previous Step.
8. Place a washer (3) onto the threads of each screw (2). Insert the screws through the grommets, and place a second washer onto the screw threads.
9. Install the USB/power port (8) to the saddlebag side wall with screws (2). Tighten to 2.8–3.3 N·m (25–30 in-lbs)
10. Feed the accessory power cable (6) and USB cable (7) and harness out through the 16 mm (0.62 in) hole in the saddlebag side wall.
11. Install the split grommet (9) with the large end facing the connector. Snap the grommet onto the power port harness outside the saddlebag. Press the grommet into the wire hole.
1Screw, self tapping (2)
2Screw, button head (2)
3Washer (2)
4Grommet (2)
5Bracket, saddlebag, USB/power port
6Accessory power cable
7USB cable
8USB/power port
9Grommet, split
Figure 6. USB/12Volt Outlet Saddlebag Installation
12. Install USB cable and power cable into USB/power port.
13. See Figure 7. Install cable (13) to accessory plug. See the service manual.
NOTE
The accessory circuit is a 15A circuit. Check the rating of any accessories used with this power supply. Do not exceed the 15 amp rating.
This device supports a wide variety of USB powered devices. Charging rates can vary with device input current, cable style and cable length.
Complete Installation
1. Secure wires as needed with cable straps.
NOTE
Place connectors where they can be easily accessed for saddlebag removal.
2. Install side cover and saddlebag, if removed.
3. Install fuel tank. See the service manual.
4. Install outer fairing. See the service manual.
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)
5. Install seat. See the service manual.
6. Install the main fuse. See the service manual.
SERVICE PARTS
Figure 7. Service Parts: USB/Power Outlet
Table 1. USB/Power Outlet
Kit
Item
Description (Quantity)
Part Number
Kit 69201087
1
Screw, self tapping (2)
3152
2
USB hub
Not sold separately
3
Adhesive tape (not shown)
77125-09
4
USB/power port
Not sold separately
5
Bracket, Tour-Pak
Not sold separately
6
Bracket, USB/power port
Not sold separately
7
Screw)
2519
Kit 69201102
1
Screw, self tapping (2)
3152
2
USB hub
Not sold separately
3
Adhesive tape (not shown)
77125-09
4
USB/power port
Not sold separately
8
Screw (2)
924
9
Washer
6485
10
Grommet (2)
11410
11
Bracket, USB/power port
Not sold separately
12
Grommet, split
11486
13
Wire harness, power port
Not sold separately
Items mentioned in text, but not included in kit:
A
Screw (2)
Not sold separately