TOUR-PAK AUXILIARY BRAKE/RUN/TURN SIGNAL CONVERSION KIT
J050812011-02-17
GENERAL
Kit Number
69200042A
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 kit is not compatible with Tour-Pak® Wrap-Around LED Light kits (Part No. 67853-10 or 67914-10).
NOTE
Some state or local entities prohibit the use of red turn signal lenses. Check state and local regulations.
Additional Parts Required
This kit requires a Tour-Pak with either original equipment (OE) wrap around rear lights, or prior or concurrent installation of a Tour-Pak Lamp Kit (Part No. 68172-06 or 68012-88E).
Electrical Contact Lube (Part No. 99861-02) or equivalent is required after battery cable disconnection. This item is available from a Harley-Davidson dealer.
WARNINGRider 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.
PREPARATION
NOTE
For vehicles equipped with security siren:
- Verify that the Hands-Free Fob is present.
- Turn the ignition key switch to IGNITION.
For ALL vehicles with main fuse:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the service manual and follow the instructions to remove the main fuse. Remove the seat. Retain all seat mounting hardware.
For ALL vehicles with main circuit breaker:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the service manual and follow the instructions to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
INSTALLATION
NOTE
It is important that the Y-harness installs electrically before any brake/run/turn signal converter module.
| 1. | See Figure 1. Locate the rear wiring harness coming out of the rear fender in the area under the seat. Touring models: Disconnect the rear fender lighting socket housing [7B] (1) from the main harness pin housing [7A] (2). Trike models: Disconnect the tail and turn signal converter module socket housing [7D] (1) from the main harness pin housing [7A] (2). | |||||
| 2. | See Figure 3. Obtain the Y-harness (2) from the kit, and mate the eight-way pin and socket housings of the Y-harness to the main wiring harness pin housing [7A] and socket and [7B] (Touring models) or [7D] Trike models. NOTE Due to variations between models, there is no single best location to secure the Y-harness. When deciding on a location for securing the Y-harness, make sure that the connectors and harness will not be bound, and that the wiring will not be pinched when the seat is installed. | 
Figure 1. Typical Rear Fender Lighting Connector (FLHTC shown) | ||||
| 3. | Remove the Tour-Pak liner. NOTE The Tour-Pak lighting harness connector is located inside the front left hand corner of the Tour-Pak. | |||||
| 4. | Disconnect the Tour-Pak lighting harness socket housing [12B] from the main harness pin housing [12A], but do not remove the harness from the Tour-Pak. | |||||
| 5. | Get the auxiliary brake/run/turn signal conversion harness (1) from the kit. Do not remove the backing from the adhesive tape on the module (A) at this time. See Figure 2. Loosely position the module (1) in the right rear corner of the Tour-Pak, on the small shelf just below the corner lamp. | |||||
| 6. | Remove and discard the original equipment (OE) grommet from the right front side of the Tour-Pak. | |||||
| 7. | Route the five-pin conduit bundle ( Figure 3 , Item B) through the grommet hole in the Tour-Pak. | |||||
| 8. | Install the new split grommet (3) around all the wiring at the hole, and work the grommet into the hole in the Tour-Pak wall. | |||||
| 9. | Get the six-way pin housing (4) from the kit. Insert the five pin terminals of the conversion harness into the correct cavities of the pin housing as follows: |
- Insert the brown wire terminal into cavity 1.
- cavity 2 is unused.
- Insert the violet wire terminal into cavity 3.
- Insert the black wire terminal into cavity 4.
- Insert the red/yellow wire terminal into cavity 5.
- Insert the blue wire terminal into cavity 6.
- Plug the pin housing into the Y-harness installed earlier in the area under the seat. Use cable straps (5) as necessary to secure the wiring.
- Plug the three-way socket housing (C) on the conversion harness to the Tour-Pak lighting harness socket housing [12B] unplugged in step 4.
- Route the red/violet wire on the conversion harness to the left bulb housing. See Figure 2. Route the red/brown wire to the right bulb housing (2).
- Press the lever on the bulb housings and twist to free them from the Tour-Pak. Snap open the bulb housings and remove the red/yellow wires with terminals. Tape the terminals against the OE harness conduit with electrical tape.
- Replace the red/yellow wires just removed with the red/violet and red/brown terminated wires from the conversion harness. Close the bulb housings and install into the Tour-Pak.
NOTE
Power to the red/yellow wires leading to the bulb housings was disconnected in Step 4.
| 1 | Auxiliary brake/run/turn signal conversion module |
| 2 | Right-side Tour-Pak lamp bulb housing |
Figure 2. Module Installation at Tour-Pak Right Rear Corner
Check Lamp Function
NOTE
Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the negative battery cable.
- Models with main fuse: Refer to the service manual and follow the instructions to install the main fuse. Models with main circuit breaker: Refer to the service manual for instructions to attach the negative battery cable. Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the negative battery terminal.
- Check for proper lamp function:
- With ignition key switch ON, the left and right Tour-Pak lamp sections and the vehicle tail lamp are illuminated.
- With brake lever or brake pedal actuation, the left and right Tour-Pak lamp sections and the vehicle tail lamp will brighten.
- With left or right turn signal actuation, the correct Tour-Pak lamp section and vehicle turn signal will flash.
- With hazard warning (emergency four-way flasher) actuation, the Tour-Pak lamp sections DO NOT FLASH.
RETURN TO SERVICE
| 1. | Remove the backing from the adhesive tape on the module (A). Position the module on the small shelf, just below the right rear corner lamp. See Figure 2. | |
| 2. | Make sure all wiring is neatly routed within the Tour-Pak. Use cable straps as required to secure wiring in place. | |
| 3. | Install the Tour-Pak liner and close the lid. | |
| 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) | ||
| 4. | Refer to the service manual and follow instructions to install the seat. |
SERVICE PARTS
Figure 3. Service Parts, Auxiliary Brake/Run/Turn Signal Conversion Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Harness, auxiliary brake/run/turn signal conversion (includes 5 Amp fuse 72331-95) | 69200041 |
2 | Y-Harness, rear wiring | 70933-10 |
3 | Grommet, split | 11507 |
4 | Pin housing, six-way, single row | 73106-96BK |
5 | Cable strap (6) | 10126 |
Items mentioned in text, but not included in kit: | ||
A | Auxiliary brake/run/turn signal conversion module | |
B | Five-pin conduit bundle | |
C | Three-way socket housing | |