TRI-BAR AUXILIARY RUNNING LIGHT/BRAKE LIGHT ASSEMBLY
J048522008-11-04
GENERAL
Kit Number
68358-07A
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This assembly is a direct replacement for the original equipment (OE) rear fender light assembly, and installs in the same manner.
Tools and Supplies Required
Loctite® 243 Threadlocker and Sealant - Blue (H-D Part Number 99642-97) is required for the proper installation of this kit.
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)
NOTE
This instruction sheet references service manual information. A service manual for this model motorcycle is available from a Harley-Davidson dealer.
Electrical Overload
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
When 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 Auxiliary Running Light/Brake Light Assembly requires up to 484 mA additional current from the electrical system.
Kit Contents
See Figure 3 and Table 1.
REMOVAL
1.
Remove the saddlebags and left side cover.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
2.
Remove the main fuse.
3.
See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2).
1Nut
2Stud plate
3Rear fascia
4TORX screw
5Lamp assembly
Figure 1. FLHX Rear Fascia and Lamp
4.
On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast.
5.
Gently open the adhesive conduit at the split line to release the rear fascia light harness.
6.
At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling.
7.
2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover.
8.
Remove the screw and chrome frame tube cover.
NOTE
ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way.
9.
See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable.
10.
2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel.
11.
See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light.
1Wire clip
2Cable strap
3Fascia light harness
4Flange nut
Figure 2. Rear Fascia Light Harness
INSTALLATION
1.
Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube.
2.
2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12].
3.
Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support.
4.
Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).
5.
2006-2008 models only: Install the chrome frame tube cover on the frame tube. Install the Phillips screw and tighten to 2.8–4.5 N·m (25–40 in-lbs).
6.
Insert the bolt (with flat washer) through the passenger seat strap and slotted hole of the saddlebag front mounting bracket. Insert the bolt into the forward hole in the chrome frame tube cover. Snug the saddlebag front mounting bracket bolt, but do not tighten.
7.
ALL models: Install the new fascia run/brake light to the fascia with two T-20 TORX screws, and incrementally tighten the screws to 2–2.5 N·m (18–22 in-lbs).
8.
Insert the flange at the top of the fascia between the flap and fender. The notch in the flange engages the locator bump on the flap when the fascia is fully installed. Spread the top of the fascia to engage the top studs at the sides of the fender.
9.
Start the six flange nuts on the studs at the sides of the fender. Apply a small dab of Loctite 243 - Blue to the stud threads. Alternately tighten the flange nuts to 3.4–5.1 N·m (30–45 in-lbs).
10.
On the left side of the motorcycle, gently open the adhesive conduit at the split line and insert the rear fascia light wires.
11.
Install the new cable straps in the same locations as those removed earlier.
12.
Install the radio antenna mast and tighten the set screw.
13.
Install the main fuse and left saddlebag.
14.
2006-2008 models only: Using an open end/box wrench, tighten the saddlebag front mounting bracket bolt to 6.8–10.8 N·m (60–96 in-lbs).
SERVICE PARTS
Figure 3. Service Parts, Tri-Bar Run/Brake Light
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Tri-Bar run/brake light unit
Not sold separately
2
Cable strap (5)
10006
3
Cable strap, anchored
("fir tree" type)
10177