high intensity discharge (hid) replacement bulb - Harley
Contents
1. cMOTOR HARLEY DAVIDSON WY J03833 INSTRUCTIONS REV 2005 12 14 HIGH INTENSITY DISCHARGE HID REPLACEMENT BULB GENERAL Part Number 68639 06 Models This replacement headlamp bulb fits e FLHT models equipped with HID Headlamp Kit 68043 04 and FLHR models equipped with HID Headlamp Kit 68094 04 NOTE Hg Lamp Contains Mercury Manage in accordance with disposal laws See http www lamprecycle org or call 1 414 343 4056 Service Manual Required AWARNING 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 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 references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents There are no Service Parts available for this kit INSTALLATION WARNING Handle bulb carefully and wear eye protection Bulb con tains gas under pressure which if not handled carefully could cause serious eye injury 00062b CAUTION Never touch the quartz bulb Fingerprints will etch the glass and decrease bulb life Grab the bulb with paper or a clean dry cloth Failure to do so c2. ingerprints will etch the glass and decrease bulb life Grab the bulb with paper or a clean dry cloth Failure to do so could result in bulb damage 00210a 7 10 Install the new bulb in the headlamp using the gasket removed earlier Connect the wire connector to the bulb assembly Slide the rubber boot back up to the bulb assembly 6 and press it into place to cover the rear of the bulb assembly Press the bulb up against the rear of the headlamp reflector and lens assembly Install the clip with the two J03833 screws removed earlier to retain the rubber boot Tighten the screws to 6 5 8 5 in Ibs 9 0 11 5 Nm NOTE Install the headlamp with the H8 Halogen high beam bulb 10 toward the bottom and the HID low beam bulb toward the top 11 12 13 Install the headlamp See HEADLAMP ASSEMBLY INSTALLATION for your model in the Service Manual Refer to the Service Manual and follow the instructions given to re install the maxi fuse later models or re con nect the negative battery cable earlier models Test the headlamp for proper operation Check the head lamp beam for proper alignment See HEADLAMP ADJUSTMENT in the Service Manual 2 of 2
3. ould result in bulb damage 00210a 1 Refer to the Service Manual and follow the instructions given to remove the maxi fuse later models or disconnect the negative battery cable earlier models J03833 2 Remove the headlamp See HEADLAMP ASSEMBLY REMOVAL for your model in the Service Manual Unplug the high beam connector from the headlamp NOTE The rubber boot 4 and bulb assembly 6 will fall away from the rear of the headlamp reflector in the following step 3 See Figure 1 Remove the two screws 2 and clip 1 from the rear of the headlamp reflector and lens assembly 3 is00728 Clip HID boot Screw Phillips head Hi Lo 6 x 5 16 in 2 Headlamp reflector and lens assembly Rubber boot HID bulb Connector HID bulb Gasket Bracket Gasket HID bulb 1 2 3 4 5 6 Bulb HID low beam 7 8 9 1 0 Bulb halogen high beam Figure 1 HID Headlamp Components 4 Pull the rubber boot 4 off of the bulb assembly 6 and slide it down the wire to expose the connector 5 5 Disconnect the wire connector from the bulb assembly 6 Remove the gasket 7 from the old bulb and set it aside for assembly to the new bulb NOTE Hg Lamp Contains Mercury Manage in accordance with disposal laws See http www lamprecycle org or call 1 414 343 4056 e Use the plastic container and insert from the new bulb to re package the old bulb 1 of2 CAUTION Never touch the quartz bulb F
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