SUPPLEMENTARY 12 VOLT POWER OUTLET
J008462021-06-29
GENERAL
This kit must be installed by an authorized Harley-Davidson dealer. Proper installation of this kit requires special materials, tools or training only available to an authorized dealer.
2014 and later models require separate purchase of Electrical Connection Kit 69200722.
Kit Number
91843-97
WARNINGRider 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)
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)
Installation
NOTE
Power outlet can be mounted on either side cover of the motorcycle, except on 1994-2007 models with cruise control, which must have the power outlet mounted on the right side cover.
| 1. | Remove seat and the side cover chosen for installation (see note above). | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
| 2. | See the service manual and remove the main fuse or disconnect battery. | |
| 3. | A 7/8 inch (2.22 cm) diameter hole needs to be drilled in the top of the side cover to mount the power outlet. It is important that the hole is properly located as follows, before cutting: a. Find a suitable location on either side cover to mount the power outlet. Use the location zones noted in Figure 1. The top surface near the front corner is recommended. An alternate location on the front/side surface is also noted in Figure 1 , but may not be available in many instances due to exhaust clearance. NOTE Placement is determined by sufficient clearance behind the cover in order to accomodate the power outlet sleeve. The selected location must be at least 1-1/4 inch (3.2 cm) diameter and 2-1/4 inch (5.7 cm) deep. This available space will vary by model, year, cruise options and installed accessories. | |
| 4. | Carefully drill a 7/8 inch (2.22 cm) diameter hole at the location identified in the prior step. Drill from the outside of the cover to the inside. | |
| 5. | Unscrew outer sleeve of socket assembly (1) from socket body. Place the socket body into the cover hole and secure the socket in place by screwing back on the outer sleeve of the socket assembly from the inside of the side cover. | |
| 6. | Connect the two spade terminals on the harness to the spades on the socket. Make sure the black wire (longer wire) is connected to the outer spade on the outer cover, and the orange wire (shorter wire) is connected to the inner spade in the center of the socket assembly. | |
| 7. | 1994-2013 models: Plug harness connector into accessory plug [4A] under the seat. See service manual for location. 2014 and later models: a. Install Electrical Connection Kit (Part No. 69200722). See instructions in that kit. b. Connect the 4-way connector of this kit, to the 4-way connector of the harness from kit. NOTE Verify that the ignition key switch is in the OFF position before installing the main fuse or connecting the battery. | |
| 8. | See the service manual to install the main fuse or connect the battery. | |
| 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) | ||
| 9. | Install seat. 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. |
| 1 | Recommended placement zone of 7/8 inch (2.22cm) diameter drill. |
| 2 | Alternate placement zone. |
Figure 1. Left Side Cover
SERVICE PARTS
Figure 2. Supplementary 12 Volt Power Outlet
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Socket assembly (includes socket body and outer sleeve) | Not Sold Separately |
2 | Socket cover | Not Sold Separately |
3 | Harness | Not Sold Separately |
4 | Black wire | Not Sold Separately |
5 | Orange wire | Not Sold Separately |
6 | Connector "4A" | Not Sold Separately |