Harley-Davidson BFR550, BFR540 User Manual

INSTRUCTIONS

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REV. 3-2-00

V-LOGO TURN SIGNAL INDICATOR FOR ROAD KING

General

This kit is designed for installation on 1994 and later FLHR (Road King) Model Motorcycles.

QTY DESCRIPTION PART No.

2 Cable strap 10065 2 Screw, machine panhead 2589 3 Connector, butt 70585-93

Read all applicable Service Manual instructions before beginning. If any procedures are not within your capabilities, or you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Incorrect installation of this kit could result in death or serious injury.

NOTE A Service Manual is available from your Harley-Davidson Dealer.

Installation

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury.

1. Disconnect battery cables, negative cable first.

2. Following instructions in applicable Service Manual,

remove the windshield.

3. Remove the phillips screw at the bottom of the of the

headlamp door (chrome ring). Remove the headlamp door.

4. Remove the seven Phillips screws to free the headlamp

housing from the headlamp nacelle.

5. Squeeze the two external tabs (if present) to remove

the wire connector at the back of the headlamp bulb. Remove the headlamp housing assembly and set aside.

6. See Figure 1. Reaching inside the headlamp nacelle,

remove the speed nut to release the chrome strip at the top of the nacelle.

7. Remove the wire form clip holding the halves of the

nacelle together at the bottom.

8. Carefully pry off the fork lock plate at the rear of the handlebar clamp shroud. Remove two Phillips screws beneath the lock plate.

9. Loosen the Phillips screw from the tab at the front of the handlebar clamp shroud (but do not remove).

10. Loosen the two acorn nuts from the left and right side fork studs.

11. Raise the handlebar clamp shroud slightly, and while separating the halves of the headlamp nacelle, remove the shroud from the vehicle.

12. Carefully align the template over the handlebar shroud cover and tape into place.

13. Exercising caution to avoid scratching, secure the shroud in a vise or use other suitable means.

14. Use a center punch and carefully punch the drill hole locations. See Figure 2. Make sure to punch indentation deep enough to keep the bit from skating during the drilling procedure.

15. Drill one 1/4” hole and two 5/32” holes as indicated on the Drill Template (attached).

1WARNING

i02098.eps

Figure 1. Nacelle and Handlebar Clamp Assembly

Kit Number 91578-00

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Fork Lock

Plate

Clamp Shroud Screws

Chrome

Strip

Handlebar

Clamp

Shroud

Nacelle

Left Side

Speed

Nut

Flat

Washer

Wireform

16. Insert wiring through hole and route under handlebar into the headlamp nacelle. Fasten V-logo to shroud cover using two panhead screws. Tighten securely.

17 With the halves of the headlamp nacelle parted slightly,

slide the handlebar clamp shroud onto the flange at the top of the headlamp nacelle while positioning the flat washer on the Phillips screw against the inside surface of the nacelle. To secure the shroud to the nacelle, tighten the Phillips screw to 10-20 in-lbs (1.1-2.3 Nm).

18. Install two Phillips screws to secure the handlebar clamp shroud to the fork lock mechanism. Install the fork lock plate.

19. Inserting the weld stud on the chrome strip into the hole at the top of the headlamp nacelle, reach inside the nacelle to install the speednut removed in Step 6. Tighten to 10-20 in-lbs (1.1-2.3 Nm).

20. Install the wireform clip to secure the halves of the nacelle together at the bottom.

21. Tighten the two acorn nuts on each side of the fork studs to 18 ft-lbs (24.4 Nm).

22. See Figure 3. Locate the Turn Signal Multilock Connector and unplug connector halves. Pull conduit back to expose wires.

23. Following instructions in Service Manual under “Sealed Butt Splice Connectors”, splice the wiring from the Vlogo to the left and right turn signal wires and to ground. (Purple-to-Purple, Brown-to-Brown, Black-to-Black). Mate the connector halves.

24. Install the wire connector at the back of the headlamp bulb.

25. Align holes in headlamp housing with those in headlamp nacelle (headlamp door bracket at bottom). Install seven Phillips screws.

26. Fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door (chrome ring) into place. Install the Phillips screw at the bottom of the headlamp door.

27. Following instructions in Service Manual, install the windshield.

28. Connect battery cables.

Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury.

CAUTION

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Figure 3. Headlamp Nacelle

Turn Signal

Connector

and Wiring

Pull

Conduit

Back to

expose

wires

i03000.eps

Figure 2. Handlebar Clamp Shroud

i02099. eps

Drill Hole

Locations

NOTE

Page 3 of this instruction sheet is the template.

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