Well before I ever wrenched on a motorcycle I worked on cars, there was a time when I even did that as a profession. I've always been pretty good at applying a strong dose of common sense to the job and figuring out when things just don't seem right.
Having previously owned BMW and Suzuki motorcycles I became accustomed to working on those machines and following the instructions provided by the manufacturers. Both manufacturers provide clear, concise instructions that are every bit as precise as their products. Anyone who could follow instructions and could tell the difference between a Phillips and Flat head screwdriver could do many straight forward tasks and fit most accessories.
With the Harley Davidson products I've learned that there is room for interpretation and that the ability sense when things aren't quite right are required for successful, or at least less frustrating, projects. I may be spoiled by the Germans and the Japanese, but it seems to me the good folks in Milwaukee like to leave out some useful bits of information, likely to make the jobs more interesting.
When installing the layback license plate and turn signal relocation kit (PN 60215-06) on my 2008 Sportster XL1200C Custom I found that most of the directions were accurate but there were certain pieces of information left out that would have been nice to have had. First of all, the Sportster Custom is low enough that unless you have pretty small hands your going to need to lift the bike to get underneath the rear fender and loosen the original license plate mounting hardware. Fortunately for me, I've hands suited for getting into tight spots.
Removing the original turn signals from the fender support required a little extra common sense as removing the parts specified in the kit instructions does not suffice. Rather, the outer chrome cover must be completely removed by loosening all of the torx bolts. At that time the nut head for the "stud" running through the turn signal mount can be accessed.
Also, when running the turn signal wires through the new, cylindrical mount on the license plate frame it is required to remove the original shrink tubing as the internal diameter of the mount is not sufficient. I had some small diameter shrink tubing on hand and once I ran the wires through the mount covered the exposed portions in the new tubing.
Finally, the kit provides instructions for removing the original connectors from the wire ends, and new connectors to attach once the wires are routed through the mount. Again, the diameter is too narrow to run the original connectors through. Problem is, attaching the new connectors can be an issue if you don't have a crimping tool sufficient to the task. I did have a tool that with a bit of care worked for me. If you're not comfortable with this than use the original connectors and instead splice the wires. If you cut back about 2-3 inches you will have plenty of room to run the wires through the mount and then solder the ends back on. Don't forget to slip the new shrink tube over the wires before you attach the ends and use a heat sink to keep from inadvertently shrinking the tubing.
Finally, once you've successfully installed the layback license plate and turn signal relocation kit you will have two holes on each side of the rear fender support chrome cover. The instructions provide part numbers for the hole plugs. What I found that worked are 2 of PN 53377-04 for the front holes and 2 of PN 68446-00 for the rear. Funny (ha ha) thing is that the 53377 hole plugs are $5.95 each while the latter are only $0.95 a piece. Go figure.
For the rest of the install, follow the Harley-Davidson instructions. Overall, it's a good kit that adds to the looks of the Sportster and get's the turn signals relocated in preparation of saddle bags.
