Harley Auxiliary Lighting Instructions

The middle bike in this photo has auxiliary lighting.

The first thing you should know is that if you own a Softail manufactured after 2006, installing an auxiliary lighting kit will be a longer and more involved job than it may seem to you now, as you languidly lean against one wall of your garage, rub your chin and consider how next to improve your ride. Since the 2007 model year, all Harleys have come equipped with Electronic Fuel Injection so electronics are everywhere, including in your fuel tank. Further, Harley recommends that the fuel tank come off then go back on when you install the motor company’s auxiliary lighting kit. Novice mechanics may confidently begin this job, but they will no longer be novices when they are done.

Instructions

Removing The EFI Fuel Tank

1. Ride your motorcycle until the fuel gauge registers less than 1/4 tank.

2. Release the fuse box cover under the right side of the seat by pulling on it. Disconnect the fuel pump fuse by sliding flathead screwdriver behind one side of the fuse.

3. Shift the bike into neutral and start the engine. After the engine dies continue to try to start the engine for several more seconds.

4. Separate the fuel supply line from the tank by sliding the fitting sleeve up and the pulling the fuel hose down.

5. Remove the Phillips screw from the rear fender seat tab with a Phillips head screw driver. Pull off the seat.

6. Remove the black wire from the negative battery post with a combination wrench.

7. Loosen the instrument panel by removing the chrome nut in the middle of the panel with an Allen wrench. Pull the two halves of the fuel pump module connector apart and remove the instrument panel.

8. Stop one end of a 5/16 inch hose with a 5/16 inch bolt. Fasten the bolt in the hose with a worm style hose clamp and a flat head screwdriver.

9. Set a large gas can near the bike. Cut the hose clamp on one end of the crossover line under the tank with tin snips.

10. Remove the unclamped end of the crossover line from the tank fitting and replace it with the unclamped end of the 5/16 inch hose. Drain the remaining gasoline from the fuel tank into the large gas can through the open crossover line.

11. Remove spilled gasoline from around the motorcycle with rags. Move the rags and gasoline outside and away from the bike.

12. Unsnap the continuous vent line and crossover line from the fittings on the bottom of the tank and set aside.

13. Remove the front and rear tank mounting bolts and their washers and nuts with an open end wrench. Pull apart the two halves of the wiring harness fuel gauge connector.

14. Remove the fuel tank.

Install Auxiliary Lights

15. Mount the mounting clamps to the left and right fork tubes with the four Allen screws in the lighting kit. Tighten the screws to 70 inch pounds of torque with a torque wrench and an Allen socket.

16. Push the wires from the two bar lights through the mounting bracket holes. Fasten the two lamps to the two brackets with the clamp blocks, retainers and washers in the lighting kit.

17.Tighten the retainers to 20 pounds with an open end socket and torque wrench.

18. Slide the inner nesting rings onto each auxiliary light bulb. Connect the black wires to the black quick connect terminals adjacent to the indexing tabs and the gray wires to the remaining quick connect terminals.

19. Lock the bulbs into the outer trim rings with the screws in the kit and a Phillips head screwdriver. Pull the accessory lamp wires through the chrome conduits included in the kit.

20. Set the accessory lighting wiring harness included with the kit in the seat pan. Stretch the longest wires to the steering head along the frame.

21. Unscrew the nut on the grounding stud next to the seat pan with an open end wrench. Slip the metal ring on the black wire in the accessory lighting wiring harness over the stud. Refasten the hex nut with an open end wrench.

22. Mate the white wiring connector to positive connector “B” on the accessory wiring included with the kit. Tie the accessory lighting wiring harness to the adjacent wires with the plastic ties included in the kit.

23. Extend the longest wires in the accessory harness past the steering head. Route the switch wires across the left side of the handlebars to the clutch lever.

24. Install the small chrome switch into the switch mounting bracket included in the kit using a Torx driver.

25. Remove the bottom screw from the clutch lever cover with a Torx socket and socket wrench. Position the tab of the switch bracket over the screw hole and replace the bottom screw. Tighten the bottom screw to 65 inch pounds with a torque wrench and a Torx socket.

26

Fasten the switch wire to the handlebar wire clips. Loosen and remove the chrome, headlight trim ring with a Phillips head screwdriver.

27

Disconnect the female connector block from the headlight plugs. Pull the black, weather proof boot off the back of the headlamp.

28

Squeeze the headlight retaining clip to remove it from the headlight assembly. Remove the headlight bulb by twisting the clip and pulling the bulb.

29

Thread the light switch wire into the headlamp housing through the rubber grommet on the back of the housing. Connect the switch wire to the yellow, low beam wire using the double-ended tube connector in the kit and wire crimpers.

30

Remount the headlamp in the headlamp housing.

31

Insert the white wire in the auxiliary wiring harness into heat shrinkable tubing from the kit. Remove 3/8 inch of insulation from the ends of the two auxiliary light wires with a wire stripper.

32

Join the three wires with the Y tube connector in the lighting kit and a crimping tool. Slide the heat shrinkable tubing over the splice and shrink with a heat gun.

Reassemble The Bike

33

Secure the loose auxiliary lighting wires to the lower fork with the clips included in the auxiliary lighting kit.

34

Reconnect the fuel tank and all hoses. Connect the negative battery cable to the negative battery post.

35

Reinsert the fuel pump fuse and close the electrical caddy cover.

36

Reinstall the seat and refuel the motorcycle.