Whelen M05ZB User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]

LED Motorcycle Lightbar

Harley-Davidson® Road King®

Installation Guide:

Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

Safety First

This document provides all the necessary information to allow your Whelen product to be properly and safely installed.
Before beginning the installation and/or operation of your new product, the installation technician and operator must
read this manual completely. Important information is contained herein that could prevent serious injury or damage.

• Proper installation of this product requires the installer to have a good understanding of automotive electronics,
systems and procedures.

• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other
vital parts could be damaged by the drilling process. Check both sides of the mounting surface before drilling
begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets into all wire
passage holes.

• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the
mounting surface with a 50/50 mix of isopropyl alcohol and water and dry thoroughly.

• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or
located in the air bag deployment area will damage or reduce the effectiveness of the air bag, or become a
projectile that could cause serious personal injury or death. Refer to your vehicle owner’s manual for the air bag
deployment area. The User/Installer assumes full responsibility to determine proper mounting location, based
on providing ultimate safety to all passengers inside the vehicle.

• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be
made. The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE
(-) battery post.

• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control to be operated safely in any driving condition.

• Do not attempt to activate or control this device in a hazardous driving situation.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination of these
lights. Do not stare directly into these lights. Momentary blindness and/or eye damage could result.

• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking
(crazing) and discoloration. Lenses in this condition have significantly reduced effectiveness and should be
replaced immediately. Inspect and operate this product regularly to confirm its proper operation and mounting
condition. Do not use a pressure washer to clean this product.

• It is recommended that these instructions be stored in a safe place and referred to when performing
maintenance and/or reinstallation of this product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightbars

For warranty information regarding this product, visit www.whelen.com/warranty

©2007 Whelen Engineering Company Inc.
Form No.14100A (090910)

Page 1

Fig. 1

Fig. 3

...wraps around the sides and top...

Long seal

starts here...

Short Seal

Here

Short Seal

Here

Fig. 2

Outer Housing

Surface

Housing

Inner Housing

Surface

The inner gasket lip
should curl inwards

as shown.

Mounting

IMPORTANT! The lightbar should be located a
minimum of 16" from any radio antennas!

This product is designed to mount in the lowest, visible
section of the motorcycle windshield.

1. Install the 3 housing edge seals (1 long seal and 2
short seals) onto the lightbar as shown (Fig. 1). Make
sure that the seal is oriented so that the lip curls
inward (Fig 2).

2. Remove the 3 screws shown from the upper section of
the windscreen (Fig. 3.).

Fig. 4

Simultaneous

...and

ends here.

IMPORTANT WARNING!

CAUTION! DO NOT LOOK DIRECTLY AT
THESE LED’S WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE
DAMAGE COULD RESULT!

3. Position the lightbar into its mounting position behind the
windscreen. When properly positioned, the holes in the
lightbar mounting tabs will be aligned with the vacant
holes through the windscreen.

4. Using the mounting hardware included with the lightbar,
secure the lightbar to the windscreen assembly.

5. Route the wires to their respective destinations (Fig. 4).
It is left to the installation technician's discretion to select
a path for these wires that will both protect them from
possible damage and not interfere with the operation of
any other vehicle components or equipment.

IMPORTANT! Before returning the vehicle to active
service, visually confirm the proper operation of this
product, as well as all vehicle components/equipment.

3 Amp fuse

(TIR3 models)

5 Amp fuse

(LINZ6 models)

(+)

Battery

(-)

Simultaneous

to +12VDC

to Ground

Sync

RED

BLACK

GREY

WARNING! All customer supplied Wires that connect to the positive
terminal of the battery must be sized to supply at least 125% of the
maximum operating current and FUSED
load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

Page 2

at the battery to carry that