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Harley's Cruise Control Kit

Tiny Robots Give the Gas
February, 2009
By John Gilbert
Photography by John Gilbert
0507Hrb Cruise01 Z
1. The Cruise Control Kit's... 
   
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1. The Cruise Control Kit's components shown here with the supplied installation hardware. See page 505 in Harley-Davidson's '05 parts and accessories catalog to determine whichpart numbers apply to your bike.
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2. In order to install our... 
   
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2. In order to install our Cruise Control Kit, Chris had toremove the seat, left saddlebag, left side cover, andair cleaner assembly.
2002 Harley Davidson Fat Boy Overhead Battery View
3. The next step was to disconnect... 
   
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2002 Harley Davidson Fat Boy Overhead Battery View
3. The next step was to disconnect the negativebattery cable and then the positivecable. With this done, he then extracted the batterywith the aid of a hook awl.
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4. In the batterybox onthe... 
   
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4. In the batterybox onthe left side thereare three predrilledholes formounting thecruise control unit.
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5. With the mounting holes... 
   
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5. With the mounting holes identified, Chrisattached the cruise cable to the unit andinstalled the three grommets on the studs withsmall diameters outward.
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6. n order tocorrectlyroute... 
   
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6. n order tocorrectlyroute the cruisecontrol cable,Chris held themodule in placenear to where itwould be mountedand fed the cablethrough the hole inthe frame crossmemberplate...
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7. ...and routed it under... 
   
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7. ...and routed it under the rear spark plugwire, continuing on the inward side of thefuel line and surrounding parts.
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8. Before carefully curving... 
   
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8. Before carefully curving the cable androuting it up under the fuel tank and overthe top of the motor stabilizer bracket, Chrisunbolted the rear of the gas tank and propped itup as far from the frame as possible.
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9. This made it possible to... 
   
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9. This made it possible to gain easieraccess and ensured the cable could bepositioned past the aforementioned parts andbetween the cylinder heads.
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10. Chris then obtained a... 
   
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10. Chris then obtained a harness retainer,identified as part number (4), from the kit'sincluded hardware and attached it to the crossmemberplate. Then he routed the cable throughthe harness retainer.
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11. In order to prepare for... 
   
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11. In order to prepare for the next step, heclipped the wire ties holding the mainwiring harness to the frame tube above the module'smounting spot. Next, he removed the fuseblock cover and located the connector plug toconnect the module into.
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12. Chris used the three flanged... 
   
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12. Chris used the three flanged locknuts (twopictured) included in the kit to mount themodule by tightening them onto the three studson the battery box...
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13. ...and then applied dielectric... 
   
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13. ...and then applied dielectric grease to theconnector and plugged it into the module..
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14. Withthemodule boltedin... 
   
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14. Withthemodule boltedin place andthe cruisecable routedbetween theheads, Chrisattached thecable to theinductionmodule.
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15. Before removing the old... 
   
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15. Before removing the old handlebar control, a1/4-inch lock washer (5/32-inch) was insertedbetween the brake lever and lever bracket toprevent any damage to the front brake light switch.
2002 Harley Davidson Fat Boy Handle Bar View
16. Using a T27 TORX driver,... 
   
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2002 Harley Davidson Fat Boy Handle Bar View
16. Using a T27 TORX driver, Chris removedthe two screws that clamped the brakemaster to the handlebar. He used a cable tie tosuspend the brake master out of the way. Usinga T25 TORX driver, he removed the switch housingscrews, then removed the friction shoe fromthe tension adjuster screw.
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17. The brass ferrules were... 
   
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17. The brass ferrules were then removedfrom the notches on the inboard side ofthe throttle grip. We saved the ferrules for reuse.
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18. To remove the gold idle... 
   
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18. To remove the gold idle cable insert andthe silver throttle cable from the lowerswitch housing, Chris applied penetrating oil andthen used a rocking motion to pull them off.
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19. He was now able to remove... 
   
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19. He was now able to remove both cablesfrom the switch housing, then separatethe switch halves.
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20. At this point Chris removed... 
   
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20. At this point Chris removed the nacelle byremoving the riser cover, center stripmolding, and then the left and right sides.
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21. He then traced the right... 
   
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21. He then traced the right side (black) electricalconnector and the left (grey) electricalconnector and disconnected both of them.
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22. With all of the old parts... 
   
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22. With all of the old parts removed, Christhen held the new right handlebar andharness assembly in their place and plugged thenew six-pin connector into where the four-pinwas unplugged.
2002 Harley Davidson Fat Boy Right Handle View
23. Reversing the order in... 
   
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2002 Harley Davidson Fat Boy Right Handle View
23. Reversing the order in which the old partswere removed, Chris installed the new parts.
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24. For the left side, Chris... 
   
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24. For the left side, Chris repeated the samesteps as the right side but used the gray plug.
2002 Harley Davidson Fat Boy Front Headlight View
25. With all of the connections... 
   
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2002 Harley Davidson Fat Boy Front Headlight View
25. With all of the connections plugged in androuted properly, Chris then reinstalled thenacelle and windshield.
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26. The only thing left to... 
   
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26. The only thing left to do was perform thecruise cable adjustment (referred to as cablelash adjustment in the service manual) and then gofind a cop to follow him around on his test ride.

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