Rocker Switch Kit for Auxiliary Accessory Housing
J026362013-11-01
GENERAL
Kit Number
71718-02
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
INSTALLATION
| 1. | See the Service Manual. Remove the seat. | |||||||||
 WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) | ||||||||||
| 2. | Disconnect battery cables, negative cable first. | |||||||||
| 3. | Determine the desired location of the switch in the housing. | |||||||||
| 4. | Remove two screws and the auxiliary accessory housing cover. | |||||||||
| 5. | Remove the mounting bracket. | |||||||||
| 6. | See Figure 1. Route the switch wires (1) through the opening in the mounting bracket (2), and engage the groove (3) on the bottom of the switch with the edge of the opening opposite the locking tab (4). Seat the switch in the opening. | |||||||||
| 7. | See Figure 2. Secure the switch to the mounting bracket by bending the locking tab over the flange at the front of the switch. NOTE See Table 1. A length of conduit is supplied with the kit. If installing several switches/accessories, a larger diameter conduit may be required to enclose all wires and connections from the auxiliary switch housing. The following conduit sizes are available from your Harley-Davidson Dealer: | 
Figure 1. Install Rocker Switch in Mounting Bracket  Figure 2. Bend Locking Tab | ||||||||
| 8. | See Figure 3. Slide the conduit over the switch wires until the conduit is as close to the bottom of the switch as possible. Secure the conduit using a cable strap. NOTE If several switches/accessories are being installed, wires/conduit may be routed through both the upper and lower holes in the lower housing. Always route wires/conduit through the lower hole first and use the upper hole as needed. Kits for right side applications will not require a housing plug or allow wires/conduit to be routed through the upper hole in the lower housing. | 
Figure 3. Install Conduit | ||||||||
| 9. | See Figure 4. Install the switch bracket with switch(es) and/or accessories in the lower housing. Route the wires/conduit through the holes in the lower housing. (See Figure 5.) | |||||||||
| 10. | See Figure 5. Install the housing plug (supplied with Auxiliary Accessory Housing Kit) in the upper hole if it is not being used. NOTE If installing multiple switches and/or accessories, hole plugs will need to be removed to allow installation. Refer to switch/accessory kit installation instructions for specific location information. In single switch/accessory installation applications, hole plugs may need to be relocated to allow installation of the switch/accessory in the desired position. |  Figure 4. Install Mounting Bracket 
Figure 5. Switch/Accessory Wire/Conduit Routing | ||||||||
| 11. | See Figure 6. Using a flat-bladed screwdriver, carefully compress the tab and remove the hole plug from the housing cover. If relocating the hole plug, snap the plug in the desired new location. | 
Figure 6. Remove/Reposition Hole Plug(s) | ||||||||
| 12. | See Figure 7. Install the housing cover using two button-head screws. Using a T-25 TORX driver, tighten screws to 35-45 in-lbs (4-5 Nm). | 
Figure 7. Install Housing Cover | ||||||||
| 13. | Determine the desired location of the rocker switch-to accessory wire splice point(s) before cutting any wires. Allow enough slack in the wires to properly route the wires and to allow for fork movement. | |||||||||
| 14. | Trim the switch and accessory wires at the splice point, allowing approximately 1-2 in. (25.4-50.8 mm) of overlap on each wire. | |||||||||
| 15. | Remove approximately 3/8 in. (9.5 mm) of insulation from the ends of the switch and accessory wires. | |||||||||
| 16. | See Figure 8. Slide the heat-shrink tubing (1) over the accessory wire (2), and crimp the electrical connector (3) to the wire using an HD 38125-8 Crimping Tool. | |||||||||
| 17. | See Figure 8. Insert the end of the switch wire (4) into the electrical connector (3), and crimp the wire to the electrical connector (3) using an HD 38125-8 Crimping Tool. |
Table 1. Conduit Sizes
Conduit | Diameter | Part No. |
|---|---|---|
No. 8 | 0.133 in. (3 mm) | 70559-71 |
No. 2 | 0.263 in. (7 mm) | 70554-69 |
5/6 | 0.312 in. (8 mm) | 70556-71 |
3/8 | 0.375 in. (10 mm) | 70552-69 |
7/16 | 0.438 in. (11 mm) | 70553-69 |
1/2 | 0.500 in. (13 mm) | 70558-71 |
WARNINGBe 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 fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
WARNINGBe sure to follow manufacturer's instructions when using the Robinair Heat Gun or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00379a)
NOTE
- Avoid directing heat toward any fuel system component.
- Extreme heat can cause fuel ignition/explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed.
- Always keep hands away from tool tip area and heat shrink attachment.
| 1 | Heat-shrink tubing |
| 2 | Accessory wire |
| 3 | Electrical connector |
| 4 | Switch wire |
Figure 8. Connect the Rocker Switch Wires to the Accessory Wires
NOTE
Protect the heat-shrink tubing from the heat source while applying heat to the electrical connector.
| 18. | See Figure 8. Slide heat-shrink tubing (1) away from the splice and, using the UltraTorch UT-100 (HD 39969), Robinair Heat Gun (HD 25070) with Heatshrink Attachment (HD 41183), or radiant heating device, heat the crimped electrical connector (3). Apply heat from the center of the crimp out to each end until the meltable sealant exudes out of both ends of the connector. Let the connector cool. | |
| 19. | See Figure 8. Slide heat-shrink tubing (1) over the splice and, using the UltraTorch UT-100 (HD 39969), Robinair Heat Gun (HD 25070) with Heatshrink Attachment (HD 41183), or radiant heating device, heat the heat-shrink tubing to encapsulate the electrical connector. Apply heat from the center of the crimp out to each end. | |
| 20. | Repeat steps 16-19 for each switch wire-to-accessory wire connection. | |
| 21. | Remove the switch provided with the accessory kit, reference on page 1. | |
| 22. | Secure (or do not install) the switch/accessory wires to the frame using cable straps as needed. | |
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) | ||
| 23. | Install battery cables, positive cable first. | |
| 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) | ||
| 24. | See the Service Manual. Install the seat. |
Service Parts
Figure 9. Service Parts
Table 2. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Switch Cap, Rocker | 71608-02 |
2 | Switch, Rocker | 71607-02 |
3 | Connector, Pre-Insulated, Seal Splice (2) | 70586-93 |
4 | Heat-Shrink Tube, 2" (2) | 70585-93 |
5 | Strap, Cable (6) | 72266-94 |
6 | Conduit, Black PVC, 25" | Not sold separately |