POWER LOCK KIT GENERAL INSTALLATION -J04427 REV Kit Number. Models. Additional Parts Required. Kit Contents

Transcription

1 -J0 REV POWER LOCK KIT GENERAL Kit Number -0, 0-0 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of (English only). Additional Parts Required 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. (00a) 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. Kit Contents See Figure and Table and Figure and Table. INSTALLATION. See Figure. Remove lid () and hinge () from saddlebag.. Remove lock () from saddlebag.. See Figure. Set drill template on hinge surface of the saddlebag aligning the template () with hinge mounting holes ().. See Figure. Drill 0. (/) inch diameter hole ().. Place the template on the back of the saddlebag () aligning front mounting grommet () and forward latch bracket ().. See Figure. Drill inch diameter hole ().. Repeat on the other saddlebag. is0 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (000a) Disconnect 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. (000a). Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual.. Remove seat following the instructions in the appropriate Service Manual. Preparing the Saddlebags for Power Locks. Remove saddlebags following the instructions in the appropriate Service Manual.. Saddlebag lid. Saddlebag hinge. Saddlebag lock Figure. Remove Lid, Hinge and Lock from Saddlebag -J0 of

2 See Figure. There are two actuator assemblies, a left side () and a right side (). If the actuator cable does not lay against the hinge wall of the saddlebag, use the other actuator. is0. Install actuator () into bottom back corner of saddlebag. Peel off the backing from the double-sided tape on bottom of actuator before positioning into saddlebag. The cable from the actuator should be tight against the hinge-side wall of the saddlebag.. Align the cam plate with the 0. hole (previously drilled). Install two inner screws to face plate (0) of the lid/hinge. Tighten finger-tight.. Push the outer cam () through the hole in the saddlebag and cam plate. Align the inner cam () to the square stock of the outer cam.. Slide the small end of the spring () over the square stock of the outer cam (). Press the spring in place with the spacer ().. Secure the assembly with the E-clip ().. Attach the cable barrel to the cam arm and tighten the locknut on the cable end.. Tighten the two inner screws to in-lbs (. Nm).. Install cover () over the cam assembly. Install the lid tether on the back of the cover (). Install screws (). Tighten the screws only to the point where the tether fabric just begins to wrinkle.. Forward latch bracket position. Mounting grommet position. Drill inch diameter hole in saddlebag back. Saddlebag back. Saddlebag hinge side. Drill 0. inch diameter hole in hinge area. Rear hinge mounting hole Figure. Drilling Template is0 0. Install strain relief bushing () into the 0.0 hole (previously drilled). Install the actuator cable into the strain relief bushing.. Install the self-adhesive clips to hold wire against side of the saddlebag.. Install the -way housing () onto the ends of the actuator wires and secure with the secondary lock.. 0. inch diameter hole Figure. Drill Hole in Saddlebag Front. Repeat Steps - for the other saddlebag. Saddlebag liners (-0, right and -0, left) are available from your Harley-Davidson dealer. is0 Install Receiver Module and Wire Harness. Remove right side cover.. See Figure. Remove bolt () and spacer () holding arm of battery caddy.. See Figure. For Models without ABS: Install receiver bracket () and spacer () to the caddy with bolt (). For Models with ABS: Install receiver bracket () to the caddy with bolt (). Spacer () can be discarded inch diameter hole. Grommet Figure. Drill Hole in Saddlebag Back Installing Power Lock in Saddlebags. See Figure. Install new lock () on saddlebag hinge. Tighten to 0-0 in-lbs (- Nm). -J0. Tighten screw to - in-lbs (- Nm). See Figure. Ensure the foot () of the receiver bracket hook onto the arm of the battery caddy ().. See Figure. Install receiver module () onto receiver module bracket () with rubber washer (), washer () and nut (). Tighten nut to 0-0 in-lbs (.-. Nm). of

3 . See Figure. Plug connector (B) into receiver module.. Route connector wires (C and E) up the front of the battery.. Install ground wire (C) onto ground stud on the motorcycle frame.. See Figure. Plug connector (E) into the B+ connector [0B]. 0. See Figure. Route wire (A) between frame and rear fender on right side of motorcycle. is0 is0. Foot of receiver bracket. Battery caddy Figure. Install Receiver Bracket onto the Battery Caddy is00. Bolt. Spacer Figure. Remove Bolt and Spacer. B+ connector [0B] Figure. Upper Frame Crossmember (Under Seat) is0. See Figure 0. Push clip fastener () into frame hole located in front of shock absorber mounting ().. See Figure. Route wires (F and G) over the rear fender.. Connect the two-pin connector (G) to the frame on the left side in front of the shock absorber (Figure 0, Item ).. See Figure. If not installing the Tour-Pak lock kit: Install the three-pin connector (F) with weather plug ().. Connect the actuator wire connectors exiting the saddlebag before locking the saddlebag.. Install saddlebags following the instructions in the appropriate Service Manual.. Spacer (for models without ABS). Receiver module bracket. Bolt. Receiver module. Rubber washer. Washer. Nut Figure. Install Receiver Module -J0 of

4 is0 0. Box and actuator assembly (right side). Box and actuator assembly (left side) (not shown). Screw (). Power lock spacer. E-clip. Spring. Cord grip strain relief bushing. Inner cam. Outer cam 0. Face plate. Cover (right side). Cover (left side) (not shown) is0 Figure. Saddlebag Assembly. See Figure. Install Tour-Pak actuator assembly () into lid of Tour-Pak. Remove backing from double-sided tape () on bottom of actuator before positioning.. Assemble lock components using washer, nut and lock guide from Step.. Remove Tour-Pak liner.. Route wires from actuator across the inside top of lid to hinge area. Hold in place with clips ().. Route wires down into the Tour-Pak bottom.. See Figure. Connect (F) to Tour-Pak harness (see Figure, Item ).. Connect the -way connector to the Tour-Pak harness after the harness is routed inside the Tour-Pak. Connect the Tour-Pak harness to the actuator. is0. Washer. Lock guide. Locknut Final Assembly Figure. Tour-Pak Lock Set. Clip fastener. Shock absorber Figure 0. Install Clip Fastener (Left Side Shown) Install Power Lock in Tour-Pak. See Figure. Remove lock set from Tour-Pak lid. Save washer (), lock guide () and locknut () for re-installation. 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. (000a). Connect the battery cables, positive (+) battery cable first, following the instructions in the appropriate Service Manual.. Install Tour-Pak liner.. Install seat following instructions in the appropriate Service Manual.. Test the power locks with key fob. Press the lock and unlock buttons to test. -J0 of

5 SERVICE PARTS is0 0 0 A G B E F D C Figure. Service Parts: Power Lock Kit Table. Service Parts Table Item 0 Kit -0 Lock assembly () Actuator assembly, right side Actuator assembly, left side (not shown) Harness, saddlebag actuator Receiver module Bracket, receiver module Washer, rubber Washer Nut Key fob () A 0-0 -J0 of

6 Table. Service Parts Table Item Drill template Spacer (for models without ABS only) Screw Clip, adhesive-backed (not shown) Secondary lock (included with items and ) Housing, -way socket (included with items and ) Power lock wire harness Weather plug (installed in [F]) Clip 0 Power lock hardware kit Wire Harness Designations A To right saddlebag module B To receiver module C To ground D Fuse holder E To battery F To Tour-Pak G To left saddlebag module BK is0 A 0 Figure. Service Parts: Tour-Pak Power Lock Kit Table. Service Parts Table Item Kit 0-0 Tour-Pak actuator Tape, double-sided -J0 of

7 Item 0 A Cable bracket Lock stop Retaining pin Lock hook E-clip Lock driver Tour-Pak power lock cover Cap screw Catch Adhesive-backed clip Tour-Pak wire harness Tour-Pak wire harness connector Table. Service Parts Table J0 of