Harley-Davidson 77197-07, 77198-07 User Manual
GENERAL
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-J04167 REV. 2006-05-02
CRUISE CONTROL KIT FOR FLHR/S MODELS
Kit Number
77197-07, 77198-07
Models
These kits fit 2007 and later FLHR (77197-07) and FLHRS
(77198-07) (Road King) model motorcycles.
Additional Parts Required
The rider's safety depends upon the correct installation
of this kit. Use the appropriate service manual pr ocedures.
If the procedure is not within your capabilities or you do
not have the correct tools, have a Harle y-Da vidson dealer
perform the installation. Improper installation of this kit
could result in death or serious injury. (00333a)
NOTE
This Instruction Sheet refers the installer to the appropriate
FLT Service Manual for many procedures.Therefore, HarleyDavidson recommends that you do not attempt to install this
kit without having a copy of the FLT Service Manual applicable
to your vehicle.
NOTE
A Service Manual for your vehicle is a vailable from any Harle yDavidson dealer.
Kit Contents
See Figure 10 and Table 1.
INSTALLATION
1. Remove seat, left saddlebag, left side cover and air
cleaner assembly following instructions in applicable Service Manual.
2. Review the "CR UISE CONTR OL-Ultra MODELS" section
in the applicable FLT Service Manual before attempting
to install this kit.
Install Cruise Control Module
T o prevent accidental vehic le start-up, whic h could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)
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. (00049a)
3. Remove battery.
4. See Figure 1. In battery box, identify the location of the
three mounting holes (on left side of panel) for mounting
the cruise control module.
Figure 1. Battery Box (right side view)
5. See Figure 10. Obtain the Cruise Control Module (1) with
cruise cable attached and three Grommets (5) from kit.
Install the grommets on studs of cruise control module
with small diameters outward.
6. See Figure 2.While holding cruise control module in place
near its mounting location, feed the cruise control cable
through the hole in frame crossmember plate and route
under rear spark plug wire staying on inner side of fuel
line components. Carefully cur ve cable toward the right
and continue routing up under the fuel tank and over the
top of the engine stabilizer bracket, then down between
cylinder heads. Leave in place temporarily. See Figure
10. Obtain a harness retainer (4) from kit and secure the
cruise cable to crossmember plate with barb as shown in
Figure 2. On California models, remove the EVAP hose
from cable clip and secure hose with one of the cable ties
(6).
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1. Cruise control cable
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2. Harness retainer
3. Rear cylinder head
4. From hole in frame crossmember plate
Figure 2. Routing Cruise Cable from Cruise Contr ol Module
to Carburetor or Induction module (left side view)
NOTE
Prior to performing the next step, it may be necessar y to cut
the wire ties securing the main harness to the frame tube
(above mounting area) and temporarily move har ness aside
to allow adequate room for cruise module installation. It may
also be necessary to move the charcoal canister hose to the
side and secure to frame tube with cable tie (8).
7. See Figure 3. Remove the fuse block cover panel by
pulling straight out from mounts and temporarily position
the cover away from the mounting area. Align the cruise
module studs (and grommets) with mounting holes in
battery box and push module firmly into position. Make
sure grommets enter mounting holes in battery box.
8. See Figure 10. Obtain the three flange locknuts (7) and
install to cruise control module studs (inside battery box).
Tighten nuts 9-11 ft-lbs (12.2-15 Nm). Locate the 10-place
connector harness (normally wire tied to frame tube next
to battery box) and cut the tie. Route downward and install
the 10-place connector into cruise module.
9. Reinstall the fuse block cover panel by sliding (side
channels) back onto mounts. See Figure 10. Obtain cable
tie/s (8) from kit. Bundle wire harnesses (mov ed to install
cruise module) along side of cruise module to allow the
side cover to be reinstalled.
10. Return to cruise cable end near carburetor or induction
module. Follow instructions in applicable Service Manual
to connect cruise cable to carburetor or induction module.
See Figure 10. Use new retaining ring (6) from kit when
installing cable end to carburetor/Induction module.
Install New Right Handlebar Control with Harness
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
NOTE
Use the eyelet of an ordinary cable strap if the cardboard insert
is not available.
1. See Figure 4. Place a 5/32 inch cardboard insert between
the brake lever and lever bracket.
1. 5/32 inch cardboard insert
1. Cruise control
2. 10-Place connector
3. Cable tie
4. Cruise control cable
5. To frame crossmember hole
Figure 3. Mount Cruise Control Module
2. Using a T27 TORX® drive head, remove two screws with
flat washers securing the handlebar clamp to the master
cylinder housing. Remove brake lever/master cylinder
assembly and clamp from the handlebar. Use a cable tie
or other means to keep the assembly out of the way.
3. Using T25 T ORX driv e head, remov e the upper and lower
switch housing screws.
4. Remove the friction shoe from the end of the tension
adjuster screw. Save friction shoe for reinstallation.
Figure 4. Install Cardboard Insert
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