CHROME AUXILIARY LIGHTING KIT
J054682011-06-23
GENERAL
Kit Number
68605-08A
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
Auxiliary lamps are not included in this kit. The desired style of lamp must be purchased separately. HDI (International) motorcycles should only use approved fog lamps.
Crimp Tool (HD-38125-8), Heat Gun (HD-25070) with heatshrink attachment (HD-41183) or Ultra-Torch (HD-39969)
NOTE
These lamps require 2.9 amps of available current from the motorcycle's electrical system.
NOTICE
It is possible to overload your 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. See an authorized Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes. (00211c)
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 and is available from a Harley-Davidson Dealer.
Kit Contents
INSTALLATION
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 given to remove the seat and disconnect the battery negative cables.
WARNING
Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)
2.
Remove the fuel tank. See FUEL TANK - REMOVAL in the service manual.
3.
See Figure 1. The mounting brackets (1) and clamps (2) are side-specific. Select the right side or left side bracket and clamp, and install on the fork tube using two button-head screws (3) from the kit. Tighten the outer screw first. Tighten screws to 8–9 N·m (70–80 in-lbs).
1Mounting bracket
2Clamp
3Button-head screws
Figure 1. Install Mounting Bracket to Fork Tube
4.
See Figure 2. Route the lamp wire (1) through the hole in the mounting bracket (2), and secure the lamp (3) to the bracket using a clamp block (4), lockwasher (5) and retainer (6) from the kit. Tighten the retainer to 22–24 N·m (16–18 ft-lbs).
1Wire
2Mounting bracket
3Lamp assembly
4Clamp block
5Lockwasher
6Retainer
7Conduit
Figure 2. Install Lamps
5.
See Figure 11. Locate the outer trim ring (24), inner nesting ring (27), screw (25), and nut (26).
6.
See Figure 3 or Figure 4. Place the inner nesting ring on the bulb.
7.
For auxiliary lamps with spade connectors: See Figure 3. Connect the black wire to the bulb spade terminal next to the bulb indexing tab on the bulb. Install the gray wire on the remaining spade terminal. For auxiliary lamps with spade connectors: See Figure 4. Connect the Multilock auxiliary lamp connector to the auxiliary lamp.
8.
Attach the bulb and nesting ring using the trim ring, screw and nut identified in Step 5.
9.
See Figure 2. Slide the conduit (7) from the kit over the lamp wire.
10.
Repeat Steps 3 through 9 for the opposite side.
NOTE
See Figure 5 for wiring harness component identification.
WARNING
When routing wires and harnesses, ensure that they are clear of moving parts, heat sources and pinch points to avoid wire damage or a short circuit, which could cause loss of control resulting in death or serious injury. (00554b)
11.
See Figure 6. Install the wiring harness. Place the relay (1) in the opening in the seat pan, and route the long leg of the harness (3) along the frame backbone.
12.
2012 and later Dyna models: Connect the 6-place Deutsch connector to the 6-place diagnostics/P&A connector on the vehicle harness. All 2006-2011 Dyna models: Cut the 6-place connector from the harness. Splice the B+ jumper harness (item 28, Figure 11 ) to the white power lead and connect the jumper to the B+ connector on the harness. See the SEALED SPLICE CONNECTORS section of the service manual.
1Bulb index tab
2Spade terminal
3Nesting ring index tab (2002 and later)
Figure 3. Auxiliary Lamp Bulb
1Lamp index tab
2Nesting ring index tab
Figure 4. Auxiliary Lamp Assembly
1Relay
2Black wire (to vehicle ground)
3Lamp switch
4White wire (to lamps)
5Unterminated wire (to headlight - yellow [lowbeam] wire)
6White wire (to battery terminal of main circuit breaker)
7Fuse block
8Long leg of harness
Figure 5. Wiring Harness Component Identification
13.
All 2006-2011 Dyna models: Install a ring terminal from the kit to the black ground lead of the harness. Connect the black ground wire (2) with the ring terminal to the ground stud under the seat, or at any good electrical ground point. Secure the kit harness to the adjacent harnesses with cable straps (Item 16, Figure 11 ).
WARNING
When routing wires and harnesses, ensure that they are clear of moving parts, heat sources and pinch points to avoid wire damage or a short circuit, which could cause loss of control resulting in death or serious injury. (00554b)
14.
See Figure 5. Route the harness past the steering head, and route the lamp switch (3) leg of the harness along the left side of the handlebar to the clutch control.
15.
See Figure 11. Remove the boot from the lamp switch and install the switch into the mounting bracket (19). Replace the boot on the switch.
NOTE
If the boot becomes worn or damaged, or is lost, replace the boot to prevent moisture from entering the switch (item 11, Figure 11 ).
16.
See Figure 8. Remove the lower screw (1) and washer from the clutch control clamp, and install the lamp switch and bracket assembly (2). Install the screw and washer and tighten to 7–9 N·m (60–80 in-lbs). International Applications: Place the fog lamp switch label (3) on the clutch control clamp.
17.
See Figure 11. Secure the lamp switch leg of the harness to the handlebar using the wire harness retainers (Item 18) as needed. Snap the retainers into the holes in the handlebar.
18.
See the service manual and remove the headlamp assembly.
NOTE
When wired as follows, the auxiliary lamps can only be operated while the main headlamp is on low beam. This conforms to many state and local laws.
19.
See Figure 9. Route the unterminated wire (1) from the switch through the grommet into the headlight housing. Splice it to the yellow (low beam) wire (2) using the Scotchlok® electrical connector (Item 14, Figure 11 ) from the kit.
NOTE
To route the wire through the grommet, push a hooked piece of wire through the grommet from the inside of the headlamp housing. Soap the toggle switch wire and pull it back through the grommet with the hooked wire.
In some applications the wire from the kit harness may not fit through the headlight housing grommet. If this is the case, splice the black wire to the yellow wire outside the headlight housing, then tape the connector to shield it from moisture.
20.
See the service manual and install the headlamp assembly.
1Relay
2Ground stud
3Long leg of harness
Figure 6. Install Wiring Harness
1Ignition module
2Recessed area
3B+ connector
Figure 7. Install Wiring Harness
1Lower clamp screw
2Lamp switch and bracket
3Lamp switch label
Figure 8. Install Lamp Switch to Clutch Control Clamp
1Unterminated wire from lamp switch
2Yellow (low beam) headlight wire
Figure 9. Splice Unterminated Wire from Switch to Headlight
21.
See Figure 10 and the SEALED BUTT SPLICE CONNECTORS section of the service manual. Slide the heat-shrink tubing (1) over the white wire (2) from the kit harness, and crimp the electrical connector (3) to the wire with the Crimp Tool.
22.
Bring both lamp wires (4) to the connector. Trim the wires, allowing approximately 1 inch (25 mm) of the wire to extend past the butt splice connector. Trim the conduit (5) approximately 1-1/2 inch (38 mm) back from the end of the wire.
23.
Remove approximately 3/8 inch (10 mm) of insulation from the end of the lamp wires.
24.
Insert the ends of both lamp wires (4) into the electrical connector (3) and crimp the wires to the connector with the Crimp Tool.
NOTE
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 on which heat shrink work is being performed.
Always keep hands away from tool tip area and heat shrink attachment.
Protect the heat-shrink tubing from the heat source while applying heat to the electrical connector.
WARNING
Be 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)
25.
Slide the heat-shrink tubing (1) away from the splice and using the UltraTorch UT-100, Heat Gun with Heatshrink Attachment, or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. 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.
26.
Slide the heat-shrink tubing back over the splice and using the same radiant heating device, heat the tubing to encapsulate the butt splice connection. Apply heat from the center of the tubing out to each end.
1Heat-shrink tubing
2White wire from kit harness
3Butt splice connector
4Lamp wires
5Conduit
Figure 10. Connect Lamp Wires to Kit Harness
WARNING
When routing wires and harnesses, ensure that they are clear of moving parts, heat sources and pinch points to avoid wire damage or a short circuit, which could cause loss of control resulting in death or serious injury. (00554b)
27.
Secure the wires to the lower fork steering bracket using the adhesive-backed clips (Item 15, Figure 11 ) from the kit.
28.
See the service manual and install the fuel tank.
29.
Connect the battery negative cable.
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)
30.
Test headlamp high and low beams, and the auxiliary lamps for proper operation. Aim the auxiliary lamps and tighten the lamp mounting nuts.
SERVICE PARTS
Figure 11. Service Parts: Chrome Auxiliary Lamp Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Housing, passing lamp (2)
68276-02
2
Bulbs, sealed beam (purchased separately)
Reference only
3
Bracket, lamp mounting, right
Not Sold Separately
4
Clamp, lamp mounting, right
Not Sold Separately
5
Bracket, lamp mounting, left
Not Sold Separately
6
Clamp, lamp mounting, left
Not Sold Separately
7
Screw, socket head, 1/4-20 x 3/4 inch, locking (4)
927A
8
Clamp block, auxiliary lamp (2)
68720-62
9
Lockwasher, internal tooth, 3/8 inch (2)
7130W
10
Retainer, lamp mounting (2)
Not Sold Separately
11
Boot, switch
67880-94
12
Label, lamp switch, HDI (international only)
68604-01
13
Connector, pre-insulated, sealed, butt splice
70586-93
14
Connector, electrical (Scotchlok, blue)
70576-68
15
Clip, adhesive-backed (4)
10102
16
Cable strap, 7.8 inch (198 mm) (12)
10181
17
Shrink tube
72266-94
18
Retainer, harness (4)
70345-84
19
Bracket, switch mounting
Not Sold Separately
20
Conduit, vinyl, 15 inch (38.1 cm) (2)
Not Sold Separately
21
Wiring harness assembly
69200182
22
Ring terminal (2)
9858
23
Switch
70370-00
24
Trim ring (2)
68725-62A
25
Screw (2)
3514
26
Nut (2)
7606
27
Ring, inner nesting
68331-02
28
B+ jumper harness
69200013