CRUISE CONTROL KIT
J044152009-10-28
GENERAL
Kit Numbers
77196-08, 77197-08
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Tools and Supplies Required
NOTE
Functionality of this kit will require a verification that cruise control has been set to "ENABLED" in the vehicle's electronic control module (ECM). This verification can ONLY be performed by a factory-trained technician at a Harley-Davidson dealer, using the most recent version of the DIGITAL TECHNICIAN ® II computer-based diagnostic software package.
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 5 and Table 1.
INSTALLATION
NOTE
if the motorcycle is equipped with the optional Harley-Davidson Smart Siren, the main fuse MUST be removed BEFORE the alarm is activated. This WILL happen within 5 seconds of turning the ignition switch to the OFF position (except for HD-Japan models). If the main fuse is not removed promptly, the siren WILL SOUND.
1. Refer to the service manual and follow the instructions given to remove the main fuse.
2. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Remove the outer fairing per the instructions in the service manual. For FLHR models: Follow the instructions in the service manual to remove only the handlebar clamp shroud. Removing the nacelle is not necessary.
a. Remove the windshield and headlamp door. Remove the headlamp housing assembly.
b. Release the chrome trim strip at the top of the nacelle.
c. Remove the two Phillips screws beneath the fork lock plate.
d. Loosen the Phillips screw at the front of the handlebar clamp shroud, and the four acorn nuts on the side of the headlamp nacelle.
e. Raise the shroud slightly, separate the nacelle halves and slide the shroud forward to remove it from the nacelle.
NOTE
Before disconnecting the handlebar switch wiring, note the wire routing.
3. For ALL models: Refer to the service manual. Disconnect the right-side handlebar MOLEX socket housing from the black six-way main harness pin housing [22B] inside the fairing or headlamp nacelle.
NOTE
A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose.
15/32-inch (4 mm) thick insert
2Brake lever
3Brake lever bracket
Figure 1. Protect Stop Light Switch
NOTICE
Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a)
4. See Figure 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket.
5. Refer to the service manual, and follow the instructions to loosen the brake hand lever/master cylinder assembly and remove the right-side upper and lower switch housing sub-assemblies from the handlebar. It is not necessary to remove the throttle control grip. For FLHR models: Refer to the service manual. Disconnect the left-side handlebar MOLEX socket housing from the gray eight-way main harness pin housing [24B] inside the headlamp nacelle. Refer to the service manual to remove the clutch hand lever and left-side upper and lower switch housing sub-assemblies from the handlebar.
6. For ALL models: See Figure 2. The friction shoe (1) is a loose fit on the end of the tension adjuster screw (2) . Make sure the shoe has been removed with the switch housing sub-assemblies, and is not lodged in the groove of the throttle control grip (4).
1Friction shoe
2Tension adjuster screw
3Right-side lower switch housing
4Throttle control grip
Figure 2. Throttle Tension Adjuster Screw and Friction Shoe
7. See Figure 1. Verify that the 5/32-inch (4 mm) thick insert is in place between the brake lever and the lever bracket. Obtain the new right-side handlebar switch housing assembly (Item 4 or 5, depending on model) from the kit. Separate the upper and lower halves of the housing assembly. Refer to the service manual, and follow the instructions to install the switch housing assembly and brake hand lever/master cylinder assembly to the handlebar.
8. Route the right-side switch harness along the same path as the original harness (along the right handlebar). Connect the pin housing to the black socket housing disconnected in Step 3.
9. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Continue at Step 11. For FLHR models: Obtain the new left-side switch housing assembly (6) from the kit. Separate the upper and lower halves of the switch housing assembly. Refer to the service manual, and follow the instructions to install the left-side switch housing assembly and clutch hand lever assembly to the handlebar.
10. Route the left-side hand control harness along the same path as the original harness (along the left handlebar). Connect the pin housing to the gray socket housing disconnected in Step 5.
11. For ALL models: See Figure 5. Use the original equipment (OE) wire harness retainers or obtain the new retainer (1) from the kit as needed, and use them to secure the handlebar switch wiring harness conduit to the holes in the handlebar. For FLTRX models: Use the new wire harness retainer (1) from the kit to secure the handlebar switch wiring harness to the hole in the radio bracket (see Figure 3 ).
Figure 3. Secure Harness to Radio Bracket
12. For FLHR models: Continue at Step 18. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: See Figure 4. Refer to the service manual, and follow the instructions to separate the two halves of fairing cap switch connector [105]. Refer to the service manual to remove the fairing cap (1) from the motorcycle.
1Fairing cap
2Flexible clamp
3Cable strap (2)
4T-25 TORX screw (2)
5Right-side switch bracket
6Right-side inboard switch position
7Socket housing [105B]
Figure 4. Fairing Cap (Right Side)
13. Bend back the flexible clamp (2) to release the switch wires from the inside of the fairing cap. Carefully cut the cable straps (3) closest to the 12-way Multilock® socket housing [105B] (7) to free the wires from the bundle.
14. Remove two T-25 TORX® screws (4) to release the right-side switch bracket (5) from the fairing cap. Gently pry the latches on the bracket outward to release the tabs on the cruise switch hole plug in the inboard position (6). Discard the hole plug.
15. See Figure 5. Install the CRUISE on/off switch (3) in the bracket inboard position.
a. Route the switch wiring through the bracket and place the switch into position.
b. Engage the tabs on the switch in the slots of the latches.
c. Gently bend the tabs upward to lock the switch into position in the switch bracket.
16. Refer to the service manual, and follow the instructions to insert the switch wire terminals into the 12-way socket housing [105B] as follows:
  • Orange/violet wire to Cavity 4.
  • Red/green wire to Cavity 5.
  • Black/green wire with terminal to Cavity 12.
  • Black/green wire without terminal, connect to the speaker switch ground wire (if so equipped). If there is no speaker switch, tape the wire end with electrical tape and secure to other wires.
17. See the service manual, and follow the instructions to:
a. Secure the switch bracket to the fairing cap with the two screws removed in Step 14.
b. Secure the cruise wiring to the wire bundle with new cable straps from the kit, and to the fairing cap with the flexible clamp. Route as shown in Figure 4.
c. Verify that the rubber grommets on each side of the fairing cap are in place.
d. Connect the 12-way socket housing [105B] to pin housing [105A] on the vehicle harness.
e. Install the fairing cap over the ignition switch housing, verifying that the grommets fully capture the handlebar and clutch cables.
f. Start the two screws (with flat washers) removed earlier, then alternately tighten to the specified torque.
g. Assemble the ignition switch.
18. Turn the handlebar to the left and right steering stops, observing the wire and cable routing for pinch points.
19. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Install the outer fairing per the the service manual. For FLHR models: Follow the instructions in the service manual to install the handlebar clamp shroud as follows:
a. If disassembled, install the Phillips screw, flat washer and nut on the handlebar clamp shroud.
b. Slide the shroud rearward down the gap in the top of the nacelle into position.
c. Mate the nacelle halves, and tighten the Phillips screw to the specified torque.
d. Secure the handlebar clamp shroud to the fork lock mechanism, and install the fork lock plate.
e. Verify that the trim strips are in place, and replace if damaged or missing.
f. Install the chrome trim strip at the top of the nacelle.
g. Tighten the four acorn nuts on the side of the headlamp nacelle to the specified torque.
h. Install the headlamp housing assembly. Install the headlamp door and windshield.
20. Locate the four-way data link connector [91A] under the right side cover. Gently pull on the connector to disengage it from the arms on the electrical bracket. Remove the rubber protective plug from the connector.
21. Refer to the DIGITAL TECHNICIAN or the Touring models electrical diagnostic manual to verify the cruise control function on the vehicle ECM.
22. Install the rubber protective plug into the data link connector, and engage the connector into the arms of the electrical bracket.
23. Verify that the ignition key switch is in the OFF position. Refer to the service manual and follow the instructions given to install the main fuse.
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
24. Turn the ignition key switch to IGNITION, but do not start the motorcycle. Turn the handlebar to the left and right steering stops, testing the handlebar control functions at each stop.
25. Apply the front brake hand lever to test operation of the brake lamp.
26. Refer to the Cruise Control section of the owner's manual for cruise control operating instructions. Test ride the motorcycle and verify that the cruise control is operating properly.
SERVICE PARTS
Figure 5. Service Parts, Cruise Control Kits
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
Kit 77196-08
FLHT, FLHTC,
FLHX, FLHXXX,
FLTRX models
1
Retainer, wire harness (1)
70345-84
2
Cable strap (6)
10065
3
Switch, fairing cap CRUISE on/off
71513-98
4
Handlebar switch housing assembly, right-side
Not sold separately
Kit 77197-08
FLHR models
1
Retainer, wire harness (5)
70345-84
2
Cable strap (2)
10065
5
Handlebar switch housing assembly, right-side
Not sold separately
6
Handlebar switch housing assembly, left-side
Not sold separately