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-J04510

REV. 2007-12-07

MOUNTING KIT FOR INTERNATIONAL MINI-BULLET STYLE LED TURN SIGNALS

GENERAL

Kit Number

69926-08

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Models

For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harleydavidson.com (English only).

Additional Parts Required

Separate purchase of Turn Signal Kit (68863-08) is required. NOTES The Turn Signal Kit (68863-08) is intended for use on HDI model motorcycles only. They are not DOT approved for use on domestic Harley-Davidson model motorcycles. The Turn Signal Kit (68863-08) only provides turn signal function and does not have a position light in the front turn signal. Proper installation of this kit requires the use of Loctite® 243 Threadlocker and Sealant - Blue (99642-97). LOCTITE can be purchased from any Harley-Davidson Dealer. 1. 2. 3. 4. Pillion Seat Seat base Inner fender Figure 1. Remove Seat and Seat Base

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The rider's safety depends 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. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 4. 5. 6. Remove left side battery cover, disconnect battery cables, negative (-) cable first, then remove battery. Remove oil tank cover (right side). Replace cap on tank to avoid contamination of oil. See Figure 2. Remove temperature sensor cable (2) from clip.

Kit Contents

See Figure 15 and Table 1.

REMOVAL

NOTE Refer to the appropriate Service Manual for specific information on the following generalized steps. 1. 2. 3. See Figure 1. Remove seat (2) and pillion (1). Remove seat base (3). Remove inner fender (4).

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1. Oil tank Figure 2. Temperature Sensor Cable

1. Right connector [19B] 2. Left connector [18B] Figure 4. Disconnect Turn Signal Connectors

INSTALLATION

Install Front Turn Signals

To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 7. 8. Remove fuel tank following the instructions in the appropriate Service Manual. Note front turn signal wiring routing and disconnect right and left front turn signal connectors [31B] from the main harness, then remove front turn signals. Save the OE mount stems for installation. See Figure 3. Push up on TSM/TSSM connector from under the battery compartment. Disconnect the handsfree antenna connector [209B] and disconnect the TSM/TSSM connector from the main harness connector [30B]. 1. See Figure 5. Apply a small amount of Loctite 243 (blue) to the threads of the ball stud (2). Install ball stud into the threaded hole of a front turn signal (3). Tighten the ball stud to 9-12 ft-lbs (12-16 Nm).

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10. See Figure 4. Note rear turn signal wiring routing and disconnect right [19B] and left [18B] rear turn signal connectors from inside the tail lamp, then remove rear turn signals.

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1. Stock set screw 2. Ball stud 3. Front turn signal Figure 5. Install Front Turn Signals 2. Install turn signal ball stud into the lever bracket, position the turn signal as desired and secure with stock set screw (1). Tighten set screw to 96-120 in-lbs (10.8-13.6 Nm). Route the turn signal wires in the same manner as the stock turn signal wires and secure with four wire retainers (Figure 15, Item 3). Repeat Steps 1-3 for the opposite side front turn signal.

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Install Rear Turn Signals

1. 1. TSM/TSSM location Figure 3. TSM/TSSM in Battery Compartment See Figure 6. Route the turn signal wiring terminals through the stalk (1), seat support (7), reflector (4), support plate (5) and the wire routing hole (3).

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2.

Install the screw (6). Tighten the screw to 70 in-lbs (8 Nm). 2.

screws (3) from kit. Tighten the screws to 50-60 in-lbs (5.6-6.8 Nm). See Figure 9. Install the control module (1) to the seat post of frame (2) from the right side. Push the module mounting bracket onto the seat post firmly in the position shown. Ensure the connector is on the bottom of the control module. See Figure 10. Connect the TSM/TSSM Y-harness (4) to the LED main harness at connector (5). See Figure 12. Connect the TSM/TSSM connector (in battery compartment) to the female end of the Y-harness. Connect the main harness connector (3) to the interconnect harness (2). Connect the hands-free antenna [209B] to the main harness [209A]. See Figure 14. Route the LED main harness up along the seat base. Route the 8-place connector and front turn signal connector between the battery compartment and the oil tank. Connect the 8-place connector to the LED module. See Figure 10. Route the rear turn signal wire harness (2 or 3) along the same route as the existing turn signal harness.

NOTE Install the violet or brown wire in cavity 1 and the black wire into cavity 2 to match the position of the mating connectors on the LED module harness. 3. Install the connectors to the terminals following the instructions in Appendix B in the appropriate Service Manual. Repeat procedure for the opposite side.

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1. 2. 3. 4. 5. 6. 7. Stalk Rear turn signal Wire routing hole Reflector Support plate Mounting screw License plate/turn signal support bracket Figure 6. Install Rear Turn Signals

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10. See Figure 13. Cable strap the rear turn signal harness to the seat base as shown. NOTE The tail light main harness connections are not used for the new LED turn signals. Do not plug the connectors into the main harness or the system will overload. 11. Connect the rear turn signal connectors to the Control Module harness. Ensure that the left turn signal is connected to the connector with the violet and black wires, and that the right turn signal is connected to the connector with the brown and black wires. 12. See Figure 10. Route front LED turn signal main harness (2 or 3) behind the seat post. Route the harness through the H-clamp and continue the routing following the main harness. 13. Connect the front turn signal connectors to the LED main harness. 14. Secure the harness to the motorcycle or main harness bundle (as appropriate) with cable straps from the kit as necessary.

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1. Left rear turn signal 2. Right rear turn signal Figure 7. Rear Turn Signals Installed

Install Control Module and Harnesses

NOTE Fill the cavities of the connectors with dielectric grease (included in kit) prior to making connections. 1. See Figure 8. Install control module (2) from Turn Signal Kit to the mounting bracket (1) from this kit using four

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1. Mounting bracket 2. Control Module 3. Socket head screw (4) Figure 8. Install Control Module to Mounting Bracket

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1. TSM/TSSM 2. TSM/TSSM interconnect harness 3. Main harness connector Figure 11. Install TSM/TSSM Y-Harness

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1. LED control module 2. Seat post of frame Figure 9. Install LED Control Module

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1. TSM/TSSM interconnect harness 2. Cable strap

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1. 2. 3. 4. 5. 6. LED control module Front or rear turn signal connection Front or rear turn signal connection TSSM interconnect Y-harness 3-place connector 8-place connector Figure 10. LED Main Harness

Figure 12. Secure TSM/TSSM Interconnect Harness

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Return to Service

NOTE Refer to the appropriate Service Manual for specific information on the following generalized steps. 1. 2. 3. Install tail lamp cover. Install fuel tank. Install oil tank cover. Fasten the temperature sensor cable to the frame with a cable tie.

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1. Cable Strap Figure 13. Secure the Rear Turn Signal Harness

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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) 5. Connect battery, positive (+) cable first, then install battery and left side cover.

1. 2. 3. 4.

Rear turn signal connection TSM/TSSM interconnect harness LED control module harness Front turn signal connection Figure 14. LED Main Harness Routing

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) 6. Install inner fender, seat base, seat and pillion.

Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)

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SERVICE PARTS

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Figure 15. Service Parts: Mounting Kit for International Mini-Bullet Style LED Turn Signals Table 1. Service Parts Table Item 1 2 3 4 5 6 7 8 9 Mount stalk, LED turn signal (2) Housing, 2-position socket, black (2) Wiring retainer (4) Mounting clip, LED controller Screw, socket head, with lock patch, #10-24 x 0.625 (4) Cable strap (6) Dielectric grease, 5 gram (not shown) Harness, LED Module Harness, TSM/TSSM interconnect Description (Quantity) Part Number 69067-08 73152-96BK 70345-84 69594-07 4644 10181 76001-04 69927-08 70482-07 4232

10 Screw, 5/16-18 x 2.75 TORX (2)

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Information

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