Buell 59439-04Y User manual

General
This kit fits all 2003 and later XB9R and XB12R (Firebolt®)
models and 2000 and later P3 (Blast®) model motorcycles.
It is designed to fit license plates measuring 7 in.x 4 in.
(10.1 cm x 17.8 cm).
See the Service Parts illustration for kit contents.
This kit requires 145 milliamps additional current from
the electrical system. When installing any electrical acces-
sory, be certain not to exceed the maximum amperage rat-
ing of the fuse or circuit breaker protecting the circuit
being modified. Exceeding the maximum amperage could
lead to electrical failures which could result in death or
serious injury.
It is possible to overload your motorcycle’s charging
system by adding too many electrical accessories. If
your combined electrical accessories operating at any
one time consume more electrical current than your
vehicle’s charging system can produce, the electrical
consumption can discharge the battery and cause vehi-
cle electrical system damage. See a Buell dealer for
advice about the amount of current consumed by addi-
tional electrical accessories, or for necessary wiring
changes. (00249b)
NOTE
This instruction sheet references Service Manual information.
A Service Manual for your model motorcycle is required for
this installation and is available from any Buell Dealer.
The rider’s safety depends upon the correct installation
of this kit. If the procedure is not within your capabili-
ties or you do not have the correct tools, have a Buell
dealer perform the installation. Improper installation of
this kit could result in death or serious injury. (00309a)
Installation, Blast Models
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
1. Refer to the Service Manual and follow the instructions
given to remove the seat and disconnect the negative
battery cable. Retain all seat mounting hardware.
2. Remove the license plate (if installed) from the vehicle.
3. See Figure 1. Using a 3/8-inch drill bit, drill a hole (1) for
wire routing through the left side of the existing license-
plate mounting bracket (2) as shown.
4. See the Service Parts illustration. Insert the grommet
(18) from the hardware kit into the new hole.
NOTE
Holes used for prior license-plate mounting can be used if
properly located.
5. Obtain the license-plate frame assembly (1) from the kit.
Position the frame against the license-plate mounting
bracket on the motorcycle, centering the frame on the
bracket.
Mark the location of the four license-plate frame mount-
ing holes on the mounting bracket. Remove the frame
and set it aside.
6. Drill four 3/8-in. diameter holes in the license-plate
mounting bracket at the marked locations.
7. Insert the license plate into the frame. Position the
frame against the license-plate mounting bracket, align-
ing the frame on the newly-drilled holes.
8. Place a flat washer (16) from the hardware kit onto one
of the screws (17) from the kit.
Insert the screw into the lower right-side mounting hole
in the license-plate frame, through the license plate, the
cover (3), and the lower right-side hole in the original
license-plate bracket.
From the back side of the mounting bracket, place a
second flat washer (16) and a nut (15) onto the screw
threads. Hand tighten the nut.
Repeat for the remaining three mounting holes.
1WARNING
1WARNING
CAUTION
1WARNING
Figure 1. Wire Routing Hole Location (Blast)
i05954
1 of 5
1New wiring routing hole location
2Existing license-plate mounting bracket
1
2
LED LICENSE PLATE FRAME
Kit Number 59439-04Y
-J02988 REV. 2-25-2004

9. Position the wires on the back of the license-plate frame
so they are not pinched in the frame. Pull the wires to
the underside of the license-plate frame through the
grommet installed in Step 4.
Tighten the four screws and nuts securely.
10. See Figure 2. Route the license-plate frame wires
alongside the existing wiring along the tail frame, secur-
ing with tie straps (13) from the hardware kit.
11. See Figure 3. Pull the wires through the pass-through
hole next to the battery underneath the seat.
Wiring Connections, Blast Models
NOTE
See the lighting circuit wiring schematic in the appropriate
Service Manual, and Figure 4 below, for wire and connection
details.
12. Disconnect the rear lighting harness connector 7A and 7B.
13. Remove the following wires and pin terminals from
housing 7A, (the main harness side of the connector):
•Black wire and pin from cavity 6
•Orange/ White wire and pin from cavity 2
•Red/ Yellow wire and pin from cavity 5
14. See the Service Parts illustration. Obtain the harness
assembly (6) from the kit. Connect the following wires and
pin terminals from the harness assembly to housing 7A:
•Black wire and pin to cavity 6
•Blue wire and pin to cavity 2
•Red/ Yellow wire and pin to cavity 5
15. Obtain the 3-way socket housing (12) from the hard-
ware kit. Connect the following wires and socket termi-
nals from the license-plate frame to the socket housing.
•Blue wire and socket into cavity 1
•Red/ Yellow wire and socket into cavity 2
•Black wire and socket into cavity 3
16. Insert the following wires and pin terminals from the
main harness to the pin housing (7) supplied with the
harness assembly:
•Orange/ White wire and pin into cavity 1
•Red/ Yellow wire and pin into cavity 2
•Black wire and pin into cavity 3
17. Connect pin housing (7) to the socket housing on the
harness assembly (6). Connect the pin housing on the
harness to socket housing (12). Re-assemble connector
halves 7A and 7B.
Proceed to Step 21.
2 of 5
-J02988
Figure 3. Pass-Through Hole Next To Battery (Blast)
i05956
Figure 2. Securing Wire Underneath Seat (Blast)
i05955
BN
O/W
V
R/Y
BK
BK
BK
V
BN
REAR
O/W
DIRECTIONAL LAMP
RIGHT
DIRECTIONAL LAMP
LEFT
LAMP
1
2
3
4
6
5
TAIL & STOP
R/Y
BK
REAR
B
LT. BE
BE
R/BK
E
7B
O/W
BN
V
BK
R/Y
1
2
3
4
6
5
7A
1
2
3
1
2
3
1
2
3
1
2
3
R/Y R/Y
BK BK
BE BE
Figure 4. Wiring Connections (Blast)
102502
1. License plate frame assembly
6. Harness assembly
7. 3-Way pin housing included
with hardware kit
12. 3-Way socket housing
from hardware kit
12
61
7

Installation, Firebolt Models
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
1. Refer to the Service Manual and follow the instructions
given to remove the seat and pillion, and disconnect the
negative battery cable. Retain all seat mounting hardware.
2. Remove the license plate (if installed) from the vehicle.
3. Remove the tail section body work. See SUBFRAME
TAIL ASSEMBLY AND BODY WORK in the appropriate
Service Manual.
4. See Figure 5. Using a 3/8-inch drill bit, drill a hole for
wire routing through the lower tail body work as shown.
5. See the Service Parts illustration. Insert the grommet
(18) from the hardware kit into the new hole.
6. Obtain the license-plate frame assembly (1) from the kit.
Insert the license plate into the frame.
7. Place a flat washer (16) from the hardware kit onto one
of the screws (17) from the kit.
Insert the screw into the lower right-side mounting hole
in the license-plate frame, through the license plate and
the cover (3).
From the back side of the cover, place a second flat
washer (16) and a nut (15) onto the screw threads.
Hand tighten the nut.
Repeat for the lower left-side mounting hole.
8. Position the frame against the license-plate mounting
bracket on the motorcycle, aligning the frame to the
mounting holes in the bracket.
9. Place a flat washer onto a screw from the kit.
Insert the screw into the upper right-side mounting hole
in the license-plate frame, through the license plate, the
cover (3), and the upper right-side hole in the original
license-plate bracket.
From the back side of the mounting bracket, place a flat
washer and nut onto the screw threads. Hand tighten
the nut.
Repeat for the upper left-side mounting hole.
10. Position the wires on the back of the license-plate frame
so they are not pinched in the frame. Route the wires,
from underneath, through the grommet installed in Step 5.
Tighten the four screws and nuts securely.
11. See Figure 6. Using a cable strap, secure the wire to
the license plate bracket.
12. Cut the existing “fir tree” strap and remove from the tail
section.
13. See Figure 7. Route the license-plate frame wires
alongside the existing wiring along the tail frame, secur-
ing with a new “fir tree” strap (14) from the kit.
14. On either side of the “fir tree” strap, secure the harness
to the existing wires with tie straps (13).
1WARNING
3 of 5
-J02988
Figure 5. Wire Routing Hole Location (Firebolt)
i05957
Figure 6. Securing Wire to License Plate Bracket (Firebolt)
i05959
Figure 7. Wiring Routing Along Tail Frame (Firebolt)
i05958

4 of 5
-J02988
Wiring Connections, Firebolt Models
NOTE
See the lighting circuit wiring schematic in the appropriate
Service Manual and Figure 8 for wire and connection details.
15. Disconnect the rear lighting harness connector 7A and 7B.
16. Remove the following wires and pin terminals from
housing 7A, (the main harness side of the connector):
•Black wire and pin from cavity 1
•Orange/ White wire and pin from cavity 3
•Red/ Yellow wire and pin from cavity 5
17. See the Service Parts illustration. Obtain the harness
assembly (6) from the kit. Connect the following wires and
pin terminals from the harness assembly to housing 7A:
•Black wire and pin to cavity 1
•Blue wire and pin to cavity 3
•Red/ Yellow wire and pin to cavity 5
18. Obtain the 3-way socket housing (12) from the hard-
ware kit. Connect the following wires and socket termi-
nals from the license-plate frame to the socket housing.
•Blue wire and socket into cavity 1
•Red/ Yellow wire and socket into cavity 2
•Black wire and socket into cavity 3
19. Insert the following wires and pin terminals from the
main harness to the pin housing (7) supplied with the
harness assembly:
•Orange/ White wire and pin into cavity 1
•Red/ Yellow wire and pin into cavity 2
•Black wire and pin into cavity 3
20. Connect pin housing (7) to the socket housing on the
harness assembly (6). Connect the pin housing on the
harness to socket housing (12). Re-assemble connector
halves 7A and 7B.
All Models
21. Refer to the Service Manual and follow the instructions
given to re-connect the negative battery cable
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider can
result in death or serious injury. (00316a)
22. Turn the ignition on, and check the license plate frame
lights and the motorcycle lamps for proper operation:
•With the ignition switch “ON”, the five red LED’s on each
side and the Buell script at the top of the frame should
be lit, along with the motorcycle’s tail lamp.
•When the brake pedal is activated, the five red LED’s
on each side should noticeably brighten, along with
the motorcycle’s stop lamp(s).
23. Refer to the Service Manual, and follow instructions to
install the seat .
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat
can shift causing loss of control, which could result in
death or serious injury. (00070a)
24. Firebolt models: Refer to the Service Manual, and fol-
low instructions to install the pillion.
After installing pillion, pull upward on front of pillion to
be sure it is locked in position. If pillion is loose, it could
shift position during vehicle operation while carrying a
passenger, resulting in loss of control of vehicle and
death or serious injury.
1WARNING
1WARNING
1WARNING
R/Y
R/Y
BK
BKBK
BK
BKBK
BN
BNBN
O/W
O/W
V
VV
22
11
11
22
11
22
11
1
8
7
6
5
4
3
2
RH TURN SIGNAL
TAIL LIGHT
[93A] [93B]
[19A] [19B]
[7B]
[18A] [18B]
LH TURN SIGNAL
[7A]
BK
BN
O/W
V
R/Y
1
2
3
4
5
6
7
8
3
21
3
21
321
321
R/Y
R/Y
BE
BE
BK
BK
R/Y
BK
BE
Figure 8. Wiring Connections (Firebolt)
102503
1. License plate frame assembly
6. Harness assembly
7. 3-Way pin housing included
with hardware kit
12. 3-Way socket housing
from hardware kit
12
6
1
7

5 of 5
-J02988
Item Description (Quantity) Part No.
1.
License plate frame assembly
(Includes items 2 - 5) Not sold separately
2. Frame Not sold separately
3. Cover Not sold separately
4. Printed circuit board Not sold separately
5. Grommet 11410
6. Harness assembly
(Includes Items 7 - 10) 70327-04
7. Pin housing, 3-way (2) 73103-96BK
8. Pin terminal (6) 73190-96
9. Socket housing, 3-way 73153-96BK
10. Socket terminal (3) 73191-96
Item Description (Quantity) Part No.
11. Hardware Kit
(Includes Items 12 - 18) Not sold separately
12.
Housing, socket (3-way) 73153-96BK
13.
Tie strap, black,
7.75 in (20 cm) long (6) 10006
14. Tie strap, push mount 10177
15. Lock nut (4) 94026-92T
16. Washer, flat (8) 6339
17. Screw, socket head, Grade 8,
1/4-20 x 7/8 in (4) 94387-92T
18. Grommet 11410
LED License Plate Frame
Date 2/04
Part No. 59439-04Y Service Parts
2
3
4
5
9, 10
8
76
12
13
14
15
18
17
16
16
7, 8
License plate
i02504