ELECTRA-GLO LIGHT BARS
J047232008-08-04
GENERAL
Kit Number
68682-09
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. | Remove seat and saddlebags from motorcycle. Save all hardware for later reinstallation. | |
 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, negative cable first. | |
| 3. | Starting on left side of vehicle, remove chrome saddlebag guard clamp. Discard inner half of clamp. | |
| 4. | Remove top front guard rail mount from upper guard rail. Locate new mount from kit. See Figure 1. Position mount (1) on guard rail (4) with mounting tab (5) positioned on inboard side of rail (4). |
| 1 | Guard rail mount |
| 2 | Wave washer |
| 3 | Screw, allen, button head, 3/8 inch |
| 4 | Saddlebag guard rail |
| 5 | Mounting tab |
| 6 | Light bar, side |
Figure 1. Side Light Bar and Saddlebag Guard Rail
- Loosely install outer left chrome saddlebag guard clamp from kit using center mounting bracket, 3/8 inch buttonhead allen screws, medium bushings and wave washers from kit. Center bracket is formed to fit over trough in center of light bar (5).
NOTE
This kit contains three different length bushings. Proper placement of these bushings is important to the correct installation of this kit. Determine differences between all bushings and follow directions carefully when installing bushings in proper locations.
| 1 | Bushing, medium |
| 2 | Female connector |
| 3 | Grommet |
| 4 | Bushing, long |
| 5 | Light bar, side |
Figure 2. Side Light Bar and Bushings
| 5. | See Figure 1. Using 3/8 inch button head allen screw and wave washer, mount side light bar (6) to front guard rail mount (1). Returning to middle mounting location, tighten bracket which was loosely installed in earlier step. | 
Figure 3. Rear Light Bar Mounting - Inboard | ||||||||||||||||
| 6. | See Figure 3. To install inner mounting plate (5) onto rear light bar (6), place a short nylon bushing into each mounting hole. Make sure mounting plate is on inboard side. Use 5/8 inch button head allen screws (1), wave washers (2), fender washers (3), and locknuts (not visible). | 
Figure 4. Rear to Side Light Bar Connection | ||||||||||||||||
| 7. | See Figure 3. Remove TORX® head screws holding guard rails to saddlebag support assembly. Place two metal P-clamps (4) over wiring harness (7) exiting rear section of light rail (6). After verifying side and rear light rails are nested properly at rear outboard mounting location (See Figure 4 ), attach inner mounting plate (5) and P-clamps (4) to saddlebag support assembly utilizing TORX head screws (See Figure 3 ). Install long nylon bushings into mounting holes at rear outboard mounting location. See Figure 4. | 
Figure 5. P-Clamp Installation | ||||||||||||||||
| 8. | Reinstall rear saddlebag clamp with rear mounting bracket using 5/8 inch button head screws and wave washers. See Figure 5. Use nylon P-clamp (1) to hold wire in place. | |||||||||||||||||
| 9. | See Figure 2. Make electrical connection between side and rear light rail. Remove rear side lens and push female connector (2) through grommet in side rail. Plug into male connector on side rail, making sure that tang is facing outward on female connector (2). Reinstall lens and trim ring. Do not over tighten trim nuts. | |||||||||||||||||
| 10. | Repeat Steps 3 through 9 for right side installation. | 
Figure 6. Accessory Electrical Connector | ||||||||||||||||
| 11. | See Figure 6. Continue to route left and right wiring harnesses along fender struts and frame, utilizing supplied cable straps. Connect left and right side harnesses under seat just in front of battery. Connect 4-pin plug into accessory connector located in same area. NOTE Failure to properly install nylon and metal P-clamps could cause wires to rub against saddlebag resulting in scratches on the saddlebags painted surface. | |||||||||||||||||
| 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) | ||||||||||||||||||
| 12. | Connect battery, positive cable first. | |||||||||||||||||
| 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) | ||||||||||||||||||
| 13. | Test lights for proper operation. Reinstall saddlebags, making sure adequate clearance exists between rear of bags and light bars. If necessary, loosen saddlebag mounting brackets and reposition saddlebags slightly forward. | |||||||||||||||||
| 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) | ||||||||||||||||||
| 14. | Tighten brackets. Install seat. |
SERVICE PARTS
Figure 7. Service Parts: Electra-Glo Light Rails
Table 1. Service Parts: Electra-Glo Light Rails
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Nut,with washer, #8-32 | See Note below. | 20 | Bracket, rear, inboard | 69737-09 | |
2 | Push clips | See Note below. | 21 | Clamp, outer, right hand | 90946-93A | |
3 | Nut, 2-way (not shown) | See Note below. | 22 | Clamp, outer, left hand | 90934-93A | |
4 | Screw, #10-24 x 1/2 inch | See Note below. | 23 | Side housing, right | Not Sold Separately | |
5 | Screw, #10-24 x 3/8 inch | See Note below. | 24 | Side housing, left | Not Sold Separately | |
6 | Washer, wave | See Note below. | 25 | Lightboard, side, right rear | 91058-93 | |
7 | Fender washer, #10 | See Note below. | 26 | Lightboard, side, left rear | 91056-93 | |
8 | Nut, #10-24 | See Note below. | 27 | Lightboard, side, right front | 91057-93 | |
9 | Bushing, side, center, 5/32 inch (medium length) | See Note below. | 28 | Lightboard, side, left front | 91055-93 | |
10 | Bushing, inside rear, 1/8 inch (short length) | See Note below. | 29 | Lens, right | 91033-93 | |
11 | Bushing, side rear, 5/16 inch (long length) | See Note below. | 30 | Lens, left | 91032-93 | |
12 | P-Clamp, steel | See Note below. | 31 | Lens, accent, right | 91039-93 | |
13 | P-Clamp, nylon | See Note below. | 32 | Lens, accent, left | 91036-93 | |
14 | Guard rail mount, right | 91031-93 | 33 | Light assembly, right, rear | 61875-09 | |
15 | Guard rail mount, left | 91030-93 | 34 | Light assembly, left, rear | 69805-09 | |
16 | Bracket, right center | 90618-93 | 35 | Cable strap (8) | 10006 | |
17 | Bracket, left center | 90615-93 | ||||
18 | Bracket, right rear | 90617-93 | NOTE: Items 1 through 13 are serviced in the hardware Kit 69806-09 | |||
19 | Bracket, left rear | 90614-93 | ||||