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ELECTRICAL CONNECTION HARNESS [325] KIT
J064502016-09-12
GENERAL
Kit Number
69201636
Models
See Table 2. For model fitment information.
This harness provides battery power, ignition/accessory power and ground connection to accessories connecting through a 3-way Molex connector.
The harness in this kit can be used to power accessories that use: Molex MX150 3-way [325].
Installation Requirements
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 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)
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)
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)
The power from this harness is fused at 10 amps through the inline fuse.
Kit Contents
See Figure 6 and Table 1.
ALL VEHICLES
    NOTE
    • The secondary lock should never be fully removed from the connector housing. Excessive force may damage the secondary lock.
    • Do not apply any lateral force; this may damage the tool or the locking finger.
    • Excessive force can damage the lock finger.
  1. See Figure 6. Release secondary lock of the Molex MX150 3-way [325] (10) on 69201637 harness (2).
    1. See Figure 1 Insert a small screwdriver into the secondary lock release.
    2. See Figure 2. Using the housing as a pivot point gently pry out on the secondary lock to unlock (2).
      Figure 1. Release Secondary Lock (Typical)
      1Locked position
      2Unlocked position
      Figure 2. Molex Connector Lock/Unlock Positions (Typical)
  2. See Figure 3 and Figure 6. Insert socket terminal end of the inline fuse harness 69201526 (1) into [325B] terminal 3 (10) of harness 69201637 (2) from kit.
    Figure 3. End View: Pin out [325B]
    1. See Figure 4. With secondary lock unlocked, align the terminal to rear of connector.
    2. Insert the terminal until it stops and locks on the lock finger with an audible click.
      Figure 4. Installing Terminal (Typical)
  1. See Figure 2. From the front of [325B], push to insert secondary lock (1).
  2. Verify that the accessory side [325A] terminal 3 is populated.
    1. If [325A] terminal 3 is populated. Go to Step 6.
    2. If [325A] terminal 3 in not populated. Go to Step 5.
  3. See Figure 6. Using the same procedure of unlocking and locking [325] as above, insert the cavity seal (9) into the accessory side [325A] terminal 3.
  4. Disconnect Battery. See the owners manual.
  5. Remove 10A fuse from inline fuse holder on 69201526 harness (1).
  6. Install the ring terminal on 69201526 harness (1) with the positive battery cable onto the positive terminal of the battery.
  7. Install the ring terminal (BK) on 69201637 harness (2) with the negative battery cable onto the negative terminal of the battery.
  8. If needed, finish connecting battery except for side covers. See the owners manual.
NOTE
Depending on the year and model the ignition/accessory power can be located in different terminals in data link connector (DLC) [91A]. Use Table 2 for all correct cavity information.
VEHICLES USING THE DLC [91A]
  1. See Figure 6. Match the 4-way [91] (4) or the 6-way [91] (5) to the vehicle.
  2. Remove wedgelock using needlenose pliers or removal tool.
  3. Install the (V/BE) terminal on 69201637 (2) into correct cavity on [91B]. See Table 2.
    1. Grasp terminal approximately 1.0 in. (25.4 mm) behind the terminal barrel.
    2. Push terminal straight into connector grommet until a click is felt.
    3. Gently pull on the wire to confirm that it is properly locked in place.
  4. Install seal pins (8) in all unused cavities.
  5. Once all terminals are in place, insert wedgelock. The wedgelock will snap into place.
  6. Route wires with adjacent main harness wiring to avoid chafing, secure with cable straps.
  7. Install 10A fuse into the inline fuse holder.
  8. Install side covers.
  9. Install seat.
172134-94GY 4-way [91B]
272136-94GY 6-way [91B]
Figure 5. Front End Views: Pin outs - 4 and 6-Way [91B]
VEHICLES NOT USING A DLC [91A]
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 owners manual.
  2. Remove seat. See owners manual.
  3. On the 69201637 harness (2), cut and remove the terminal end on the (V/BE).
    4. NOTE
    If any copper wire strands are cut off of the wire core, trim the end and strip the wire again in a larger gauge stripper.
  4. Strip insulation off the (V/B) wire lead 3/8 in. (9.5 mm).
    5. NOTE
    See Table 2. The switched power (O/W) on vehicles 2003 and prior must be accessed at the rear lighting [7]. The terminal may vary by year and model.
  5. Access the rear lighting [7] and locate the (O/W).
  6. Leaving 1 in. (25 mm) relief from [7] cut (O/W).
  7. Strip insulation off both the (O/W) wire leads 3/8 in. (9.5 mm).
  8. Using the PACKARD CRIMPING TOOL (Part Number:HD-38125-8), open the ratchet by squeezing the handles closed.
  9. Match the connector color to the wire gauge crimp die in the jaws. Insert one end of the sealed connector.
  10. Gently squeeze the handles until the connector is held in the jaws.
  11. Feed the stripped end of a wire (O/W) on main harness side into the sealed connector until the wire stops inside the metal insert.
  12. Squeeze the handles tightly closed to crimp the leads in the insert. The tool automatically opens when the crimping is complete.
  13. Slide the connector to the other half of the metal insert. Insert the stripped wire lead from the connector side of the (O/W) and also the stripped wire lead of the (V/BE) until they both stops. Crimp the lead in the insert.
    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)
  • Avoid directing heat toward any electrical system component that is not being serviced.
  • Always keep hands away from tool tip area and heat shrink attachment.
  1. Use a ROBINAIR HEAT GUN (Part Number:HD-25070) with a HEAT SHIELD ATTACHMENT (Part Number:HD-41183), to heat the connector from the center of the crimp out to each end.
  2. Inspect the seals.
    1. Allow the splice to cool and inspect the seal. The insulation should appear smooth and cylindrical. Melted sealant will have extruded out the ends of the insulation.
  3. Route wires with adjacent main harness wiring to avoid chafing, secure with cable straps
  4. Install main fuse.
  5. Install 10A fuse into the inline fuse holder.
  6. Install side covers.
  7. Install seat.
SERVICE PARTS
Figure 6. Service Parts, Electrical Connection Harness Kit
Table 1. Service Parts, Electrical Connection Harness Kit
Item
Description
QTY
Part Number
1
Harness, wire - inline fuse
1
69201526
2
Harness, wire - electrical connection
1
69201637
Not Sold Separately
3
Butt splice, sealed
1
70586-93
4
Housing, 4-way socket - gray - [91]
1
72134-94GY
5
Housing, 6-way socket - gray - [91]
1
72136-94GY
6
Secondary lock, 4-way socket
1
72154-94
7
Secondary lock, 6-way socket
1
72156-95
8
Seal pin
5
72195-94
9
Cavity seal, Molex MX150
1
72473-07
10
Housing, 3-way socket - black - [325]
1
72512-07BK
Table 2. Connector Cavity Usage
Vehicle Yr/Models
Power From **
Kit Connector Number
V/BE Into Cavity
14 - 16
Touring
[91]
72136-94GY
5
11 - Present
Softail
12 - Present
Dyna
14 - Present
Sportster
04 - 13
Touring
[91]
72134-94GY
4
04 - 10
Softail *
04 - 11
Dyna *
04 - 13
Sportster *
04 - Present
V-Rod *
94 - 03
Touring
[4]
72134-94GY
3
03 - Earlier
All
[7]
Butt Splice
N/A
* This procedure shows connecting to the IGN power through the DLC [91A]. But power on [325] terminal 2 can also be connected to ACCY power. See the service/electrical diagnostic manuals.
** See electrical diagnostics manual for connector location.