-J04167 REV.

2006-05-02

CRUISE CONTROL KIT FOR FLHR/S MODELS

GENERAL
Kit Number
Disconnect negative (-) battery cable first. If positive (+)
77197-07, 77198-07 cable should contact ground with negative (-) cable con-
Models nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
These kits fit 2007 and later FLHR (77197-07) and FLHRS
(77198-07) (Road King) model motorcycles. 3. Remove battery.

Additional Parts Required 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.

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The rider's safety depends upon the correct installation
of this kit. Use the appropriate service manual procedures.
If the procedure is not within your capabilities or you do 1
not have the correct tools, have a Harley-Davidson 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, Harley-
Davidson recommends that you do not attempt to install this
kit without having a copy of the FLT Service Manual applicable
to your vehicle.
NOTE Figure 1. Battery Box (right side view)
A Service Manual for your vehicle is available from any Harley-
Davidson dealer. 5. See Figure 10. Obtain the Cruise Control Module (1) with
cruise cable attached and three Grommets (5) from kit.
Kit Contents Install the grommets on studs of cruise control module
See Figure 10 and Table 1. with small diameters outward.

INSTALLATION 6. See Figure 2. While holding cruise control module in place

near its mounting location, feed the cruise control cable
1. Remove seat, left saddlebag, left side cover and air through the hole in frame crossmember plate and route
cleaner assembly following instructions in applicable Ser- under rear spark plug wire staying on inner side of fuel
vice Manual. line components. Carefully curve cable toward the right
and continue routing up under the fuel tank and over the
2. Review the "CRUISE CONTROL-Ultra MODELS" section
top of the engine stabilizer bracket, then down between
in the applicable FLT Service Manual before attempting
cylinder heads. Leave in place temporarily. See Figure
to install this kit.
10. Obtain a harness retainer (4) from kit and secure the
Install Cruise Control Module 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).
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)

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 8. See Figure 10. Obtain the three flange locknuts (7) and
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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
2 the 10-place connector into cruise module.

1 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 (moved to install
cruise module) along side of cruise module to allow the
side cover to be reinstalled.
4 10. Return to cruise cable end near carburetor or induction
3 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.
1. Cruise control cable
2. Harness retainer Install New Right Handlebar Control with Harness
3. Rear cylinder head
4. From hole in frame crossmember plate
Figure 2. Routing Cruise Cable from Cruise Control Module Do not remove or install the master cylinder assembly
to Carburetor or Induction module (left side view) without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
NOTE installing the master cylinder assembly without the insert
Prior to performing the next step, it may be necessary to cut in place may result in damage to the rubber boot and
the wire ties securing the main harness to the frame tube plunger on the front stoplight switch. (00324a)
(above mounting area) and temporarily move harness aside
to allow adequate room for cruise module installation. It may NOTE
also be necessary to move the charcoal canister hose to the
Use the eyelet of an ordinary cable strap if the cardboard insert
side and secure to frame tube with cable tie (8).
is not available.
7. See Figure 3. Remove the fuse block cover panel by
1. See Figure 4. Place a 5/32 inch cardboard insert between
pulling straight out from mounts and temporarily position
the brake lever and lever bracket.
the cover away from the mounting area. Align the cruise
module studs (and grommets) with mounting holes in
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battery box and push module firmly into position. Make
sure grommets enter mounting holes in battery box.

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1
1
4
3

5 2
1. 5/32 inch cardboard insert
Figure 4. Install Cardboard Insert

2. Using a T27 TORX® drive head, remove two screws with

flat washers securing the handlebar clamp to the master
1. Cruise control cylinder housing. Remove brake lever/master cylinder
2. 10-Place connector assembly and clamp from the handlebar. Use a cable tie
3. Cable tie or other means to keep the assembly out of the way.
4. Cruise control cable
5. To frame crossmember hole 3. Using T25 TORX drive head, remove the upper and lower
switch housing screws.
Figure 3. Mount Cruise Control Module
4. Remove the friction shoe from the end of the tension
adjuster screw. Save friction shoe for reinstallation.

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 NOTE
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The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
5. See Figure 5. Remove the brass ferrules from the notches
1
on the inboard side of the throttle control grip, then remove
ferrules from the cable end fittings. Save ferrules for re-
installation.
3
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2

1. Lower cable housing

2. Idle cable insert (gold)
1 3. Tension adjuster screw
3 2 4. Throttle cable insert (silver)
Figure 6. Upper Right Handlebar Switch Housing

9. Trace the right handlebar wiring harness to the 6-place

Molex connector and disconnect connector halves. Note
4
5 the existing harness routing and cable ties securing har-
ness to handlebars. Remove and discard the right hand
control and harness assembly.
10. See Figure 10. Obtain the new Right Handlebar Control
and Harness Assembly (2) from kit. Install the new harness
1. Throttle cable 6-place connector in same place as connector removed
2. Idle cable in Step 9. Locate the unused 3-place connector half (next
3. Groove to the 6-place) and install the 4-Place connector from the
4. Notch new harness to the 4-place connector in headlamp
5. Ferrule assembly.
Figure 5. Remove Throttle and Idle Control Cables 11. At new handlebar control assembly, hold the lower switch
housing with concave side facing upward. Install the ten-
NOTE sion adjuster screw and spring with the friction shoe (saved
It is not necessary to remove the throttle control grip. from Step 4) so that pin hole is over the point of the Ten-
sion adjuster screw. Adjust the tension adjuster two or
6. See Figure 6. Pull the crimped inserts at the end of the
three turns to hold assembly in place.
throttle and idle control cable housings from the lower
switch housing. For best results, use a rocking motion NOTE
while pulling. Place a drop of light oil on the retaining rings, The friction shoe is a loose fit and may fall out or become dis-
if necessary. Save inserts for re-installation. lodged if the switch housing is turned upside down or shaken.
7. Remove the cables from the switch housing, then separate 12. Refer to Figure 6. Push the throttle and idle control cables
the upper and lower switch halves. into the lower switch housing until they snap into place.
Perform the following:
8. Follow the instructions in applicable Service Manual and
remove windshield and nacelle. a. Obtain the crimped inserts removed in Step 6. Note
the different diameter inserts crimped into the end of
NOTE the throttle and idle control cable housings.
When performing the next Step, the right side Molex Electrical
Connectors are Black; the left side Molex Electrical Connectors b. Push the larger diameter insert (silver) on the throttle
are Grey. cable housing into the larger hole in front of the ten-
sion adjuster screw.
c. Push the smaller diameter insert (gold) on the idle
cable housing into the smaller hole at the rear of the
tension adjuster screw.

NOTE
To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.
13. Slide the throttle control grip towards motorcycle until it
bottoms against the closed end of the handlebar. Rotate

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 the grip so that the ferrule notches are at the top. To pre- 21. Remove the cardboard insert between the brake lever and
vent binding, pull the grip back about 1/8 inch (3.2 mm). lever bracket.
14. Refer to Figure 5. Position the new lower switch housing 22. See Figure 10. Obtain two harness retainers (4) from kit.
beneath the throttle control grip. Install the brass ferrules Adjust the harness so it runs under the handlebar and
onto the cables so that the end fittings seat in the ferrule secure harness conduit to holes in lower side of handlebar
recess. Seat the ferrules in their respective notches on by inserting barbed ends of retainers.
the throttle control grip. Verify that the cables are captured
in the grooves molded into the grip. Install New Left Handlebar Control with Harness

15. Position the upper switch housing over the handlebar and NOTE
lower switch housing. Prior to performing the next step, cut all cable ties securing left
control switch harness to handlebars and discard.
16. Verify that wire harness conduit runs in the depression at
the bottom of the handlebar. Be sure that the upper switch 1. Trace the left control switch harness wiring to the head-
housing harness will not be pinched under the handlebar lamp area (with nacelle removed) and locate the Grey 8-
when the switch housing screws are tightened. place Molex Connector. Disconnect the handlebar switch
half from the connector.
NOTE
Do not remove the 5/32 inch cardboard insert wedged between 2. Using a T27 TORX® drive head, remove the two screws
the brake lever and lever bracket. Removal will result in with flat washers securing the handlebar clamp to the
damage to the rubber boot and plunger of the Front Stoplight clutch lever bracket. Remove the clutch hand lever
Switch during installation of the master cylinder assembly. assembly and clamp from the handlebar. Save all hard-
ware for reinstallation.
17. Start the upper and lower switch housing screws, but do
not tighten. 3. Using a T25 TORX® drive head, remove the upper and
lower switch housing screws. Save switch housing screws
18. See Figure 7. Position the brake lever/master cylinder
for reinstallation. Remove the left handlebar control and
assembly inboard of the switch housing assembly
harness and discard.
engaging the tab on the lower switch housing in the groove
at the top of the brake lever bracket. NOTE
It is not necessary to remove the left handlebar grip. Leave
19. Align the holes in the handlebar clamp with those in the
grip in place.
master cylinder housing and start the two screws (with flat
washers). Position the assembly for rider comfort. Begin- 4. See Figure 10. Obtain the new Left Handlebar Control
ning with the top screw, tighten the screws to 60-80 in-lbs with Harness (3) from kit.
(6-9 Nm) using a T27 TORX® drive head.
5. See Figure 8. Position the left switch control upper (1) and
lower (2) housings onto the handlebar (3). Be sure that
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rib (4) on outboard side of switch housings fits in groove
(5) molded into the grip.
1
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2 1
3

3
4

1. Brake lever bracket

6
2. Groove 5
3. Tab
4. New switch assembly with cruise Set/Resume
2
Figure 7. Installing Brake Lever/Master Cylinder Assembly
to Right Switch Housing Assemblies 1. Left switch control upper
2. Left switch control lower
NOTE 3. Handlebar
When performing the following Step, tighten the lower switch 4. Rib
housing screw first so that any gap between the upper and 5. Groove
lower housings is at the front of the switch. 6. Wire harness conduit

20. Using a T25 TORX® drive head, tighten the lower then Figure 8. Installing Left Handlebar Switch Housing
upper switch housing screws to 35-45 in-lbs (4-5 Nm).

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 6. Verify that the wire harness conduit (6) runs in the groove NOTE
at the bottom of the handlebar. Be sure that the upper Always tighten the lower switch housing screw first so that any
switch housing harness will not be pinched under the gap between the upper and lower housings is at the front of
handlebar when the switch housing screws are tightened. the switch.
7. Start the upper and lower switch housing screws saved 11. Route left hand control harness under handlebar and down
in Step 3, but do not completely tighten at this time. to headlamp area (with nacelle removed). Locate the 8-
place Molex Connector and connect the 6-place control
8. See Figure 9. Position the clutch hand lever assembly harness connector.
inboard of the switch housing assembly engaging the tab
on the lower switch housing in the groove at the bottom 12. Locate the unused 3-place Molex Connector and connect
of the clutch lever bracket. Be sure that harness will not the 3-place control harness connector.
be pinched when installing handlebar clamp. Harness
13. See Figure 10. Obtain two wire harness retainers (4) from
should reside in recess between handlebar clamp and
kit and secure harness to handlebar in two places by
clutch lever bracket.
installing barbs on retainers into holes in handlebar.
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fairing nacelle and windshield.
3 15. Follow instructions in Service Manual and install left sad-
dlebag, left side cover and air cleaner assembly.
4

Connect positive (+) battery cable first. If positive (+) cable

should contact ground with negative (-) cable connected,
1 the resulting sparks can cause a battery explosion, which
2 could result in death or serious injury. (00068a)
16. Reconnect battery, positive (+) cable first.
1. Clutch lever bracket 17. Install seat.
2. Switch housing assembly
3. Groove
4. Tab
Figure 9. Positioning Clutch Lever Bracket with Left After installing seat, pull upward on seat to be sure it is
handlebar Switch Housings locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
9. Align the holes in the handlebar clamp with those in the serious injury. (00070b)
clutch lever bracket and start the two screws (with flat
Cruise Cable Adjustment and Final Test
washers) saved from Step 2. Position the assembly for
rider comfort. Beginning with the top screw, tighten the 1. Perform cruise cable adjustment. See "Cable Lash Initial-
screws to 60-80 in-lbs (7-9 Nm) using a T27 TORX® drive ization" in applicable Service Manual.
head.
2. Refer to cruise control section in Owner's Manual for cruise
10. Using a T25 TORX® drive head, tighten the lower and control operating instructions.
upper switch housing screws to 35-45 in-lbs (4-5 Nm). 3. Test ride motorcycle and verify cruise control is operating
properly.

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SERVICE PARTS
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3
2

6 1 4
5

Figure 10. Service Parts: FLHR/I and FLHRS/I Cruise Control Kit

Table 1. Service Parts Table

Item Description (Quantity) Part Number Item Description (Quantity) Part Number
Model FLHR/I, Kit 77197-07 Model FLHRS/I, Kit 77198-07
1 Assembly, cruise control w/har- 70955-04 1 Assembly, cruise control w/har- 70955-04
ness ness
2 Assembly, hand control (right) 70419-07 2 Assembly, hand control (right) 70437-07
3 Assembly, hand control (left) 70434-07 3 Assembly, hand control (left) 70438-07
4 Retainer, wire harness (5) 70345-84 4 Retainer, wire harness (5) 70345-84
5 Grommet (3) 11497 5 Grommet (3) 11497
6 Ring, retaining 11193 6 Ring, retaining 11193
7 Nut, flange locking (3) 7499 7 Nut, flange locking (3) 7499
8 Ties, wire (2) 10065 8 Ties, wire (2) 10065
Items mentioned in text, but not included in kit: Items mentioned in text, but not included in kit:
A Cruise control cable A Cruise control cable

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