A POOR MANS GUIDE TO RELOCATING HARLEY SPORTSTER REAR SIGNAL LIGHTS

I take pleasure in modifying my bike, my way. I take more pride in a do it yourself home made part than one I picked up at the dealer. If you are a do it yourself guy or gal this will make your bike a little more useful , a little more your own and save you a wad of cash.


It takes about a half hour and costs about five dollars in materials to relocate your rear signal lights from the stock position to the fender of your bike. This procedure applies to 04-06 Sportsters. It will probably work on many other years. I assume that you know how to perform basic wiring, drilling and other tasks. If you are not sure find a helper who can walk you through these steps. The hardest part is removing the wires from the connectors without damaging the small brass clips.


First a little CYA:
• If you are not capable of drilling four holes in your fender and connecting four wires without screwing up, pay your Dealer a couple hundred bucks to install an official Harley relocation kit.• When drilling into your fender use a drill stop to avoid punching a hole in your tire.• Although this procedure worked perfectly fine on my bike there is a potential for stress and vibration to damage your fender.• There is a potential for damaging your electrical connectors when removing the wires.


Now if I haven’t scared you away let’s get started on this fairly simple procedure.


Step One. Disconnect one of your battery cables just in case. Using a crayon or grease pencil and a level mark a horizontal line on the fender where you plan to install the lights.

Step Two. Jack up the bike so that the rear wheel hangs freely in order to give you room to work under the fender.

Step Three. Remove your tail light lens by unscrewing the two Philips screws.

Step Four. Locate the two connectors that feed the turn signals. There are four connectors that plug into the printed circuit board. One is for the tail light, it has three wires. One is the feed from the motorcycle with several wires. The connectors for the signal lights have two wires each.

Step Five. Remove the signal light connectors from the circuit board one at a time. Make a note of the color of the wires that run to the right and left lights respectively and their orientation in the connectors.

Step Six. Remove the connectors from the signal light wires. (I use a small straight jewelers screw driver from the back of the connect to depress the small retaining clip) The connectors will not fit through the holes in your fender when you remove the lights in a later step. DON’T CUT THE WIRES, REMOVE THEM FROM THE CONNECTORS.

Step Seven. Remove the single Phillips screw that secures the printed circuit board.

Step Eight. Feed the signal light wires back into the fender. Remove the wires from the holders underneath the fender.

Step Nine. Remove the nuts that secure the signal light stalks. Remove the signal light assemblies, carefully feeding the wires through the holes.

Step Ten. Carefully mark two holes in each side of the fender where you want the lights to mount on the line from step one. I recommend that you locate the turn signals on the flat portion of the fender to assure that they face directly behind the bike. I made a template to locate the holes when I did mine.

Step Eleven. Remove the factory mounting bolt from the light assembly.

Step Twelve. Feed the wires through the hole in the fender. Attach the signal lights by inserting a bolt through the large washer and fender. Loctite is strongly recommended. Note 1 &2

Step Thirteen. Feed the wires back to the printed circuit board. Replace the Phillips screw that secures the printed circuit board. Reinsert the wires into the correct connectors. Plug in the connectors. Reconnect your battery. Check to make sure the lights operate properly.

Step Fourteen. Secure your Tail light lens with the two Phillips screws.

Step Fifteen. Remove your bike from the jack.

Tools and materials needed.


Two bolts to replace the factory signal light bolts. 1/4" 20 x 3/4 inch.Two large washers approximately 1" OD sometimes called fender washers. ( I prefer stainless steel bolts and washers if I can find them.)

Drill and bits, Phillips screw driver, Rat tail file, Loctite. I use a piece of wood as a drill stop.
I used red Loctite after I made sure the lights would be oriented correctly.

Note 1: The light stalk attaches to your bike with a bolt and a locator stud. I used a rat tail file to remove material as needed from the locator hole in order to make minor adjustments to the orientation of the stalks.

Note 2: The large washer is used to strengthen the fender where the lights are mounted. After you finish this project check out my Poor mans guide to fabricating and installing saddlebag brackets.


Ride Safe!
Don

When you get that bike back on the road check out my store: HTTP://DONSCYCLEWARE.COM
YOUR SOURCE FOR QUALITY MOTORCYCLEGEAR .

WHILE YOUR THERE CHECK OUT THE XL SERIES SADDLEBAGS DESIGNED FOR HARLEY SPORTSTERS