Billet Headlamp Shell Instruction Sheet - Harley
Contents
1. 00275a J03018 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled NOTE Before disconnecting battery fuel pressure must be relieved from the fuel lines of the EFI system Refer to the applicable Service Manual for instructions WARNING Stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002a 3 FXST B D models Remove fuel tank Refer to FUEL TANK CARBURETED or FUEL TANK EFI in Service Manual FXDWG models Remove fuel tank Refer to FUEL TANK in Service Manual WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 4 Disconnect battery cables negative cable first 5 See Figure 1 Disconnect headlamp connector 1 from vehicle harness D Remove nut 2 screw 3 and trim ring 4 from head lamp NOTE Save the following items for reuse e Lens assembly 5 includes gasket and boot e Adapter ring 7 e Wiring harness 102. 5 and bottom of headlamp shell Starting near shims and alternating from side to side carefully pry trim ring from headlamp shell 7 See Figure 14 Using a needle nose pliers remove retaining ring 1 from groove in headlamp shell 2 8 Carefully pull lens assembly 3 out of headlamp shell and disconnect wiring connector block 4 from bulb prongs 9 Remove boot 5 and gasket 6 and gasket 7 from lens assembly NOTICE 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 could result in bulb damage 00210a 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 10 Replace headlamp bulb according to the procedure in the applicable Service Manual 8 of 10 is03107 1 Retaining ring 2 Headlamp shell 3 Lens assembly 4 Wiring connector block 5 Boot 6 Gasket 7 Gasket Figure 14 Remove Lens Assembly Headlamp Assembly 1 Softail and Dyna Models a 2004 and earlier See Figure 7 Install gasket from kit over boot and existing gasket Position gasket according to the adapter ring wave shape or L shape cross section equipped with lens assembly b 2005 and later See Figure 8 Install gasket from kit over boot and existing gasket Position gasket according to the adapt
3. includes wiring connector block 6 headlamp connector 1 and grommet 9 Lockwasher 12 N Remove lens assembly 5 and disconnect wiring con nector block 6 from bulb prongs 1 of 10 Please dispose of materials responsibly is03077 Lens assembly includes gasket and boot Wiring connector block 1 Headlamp connector 2 Nut 3 Screw 4 Trimring 5 6 7 Adapter ring wave shape cross section shown 8 Headlamp shell assembly 9 Grommet 10 Headlamp wire harness includes 1 6 and 9 11 Bolt 12 Lockwasher Figure 1 Headlamp Assembly Softail and Dyna Models is03101 1 Lens assembly 2004 Earlier 2 Lens assembly 2005 Later Figure 2 Headlamp Lens Assembly 8 Remove adapter ring 7 from headlamp shell assembly 8 NOTE Record the location of the wires in the connector before removing J03018 9 Remove headlamp connector 1 from headlamp wire harness using a pick tool Snap on TT600 3 10 Work the grommet 9 through the hole in the headlamp shell from outside of shell using a small flat bladed screwdriver and remove headlamp wire harness with grommet 10 from headlamp shell If harness is equipped with an internal ground wire cut ground wire off and tape end of wire with electrical tape 11 Remove bolt 11 lockwasher 12 and headlamp shell assembly 8 VRSCA Models Remove original equipment headlamp assembly Refer to
4. two layers of masking tape on both sides of windshield This tape provides a surface on which to mark the cut as well as to protect the windshield while cutting 2 Mark amount to be trimmed 1 on the tape Maintain existing radius 2 when marking new opening 3 Using a saber saw with a fine toothed blade carefully cut new opening on windshield J03018 4 5 Clean edges of new opening with a fine grit grinding wheel Remove tape is02276 ro 1 Amount to be trimmed 2 Radius 3 Area to be removed Figure 11 Windshield Trimming Dimensions 7 of 10 LENS AND BULB REPLACEMENT Disassembly AWARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 1 Softail and Dyna Models a Remove seat according to the instructions in the Service Manual b Disconnect battery cables negative cable first VRSC Models a Remove right side cover and maxi fuse Refer to MAXI FUSE in Service Manual 2 See Figure 12 Cover tip of small slotted screwdriver with duct tape and insert tip of screwdriver into opening 1 at bottom of headlamp shell Twist screwdriver to move bottom of trim ring 2 out approximately 0 12 in 3 mm NOTES If a cotter pin extractor pick with a 90 bend is available it can be used as a sm
5. Instruction Sheet J03720 for procedures NOTE VRSCA models require the separate purchase of Headlamp 68297 05 which is available from a Harley Davidson dealer VRSCB Models Remove original equipment headlamp assembly Refer to Instruction Sheet J03720 for procedures NOTE VRSCB models use the original equipment headlamp and gasket 2 of 10 INSTALLATION Wiring Harness and Headlamp Mounting Block Assembly NOTE Use caution during installation to prevent scratching the headlamp shell mount and mounting block 1 See Figure 3 Feed headlamp wire harness with grommet 1 through hole in billet headlamp shell 2 but do not seat grommet 3 in hole 2 Softail and Dyna Install harness wires into connector 4 in same locations as noted in removal VRSC Refer to Instruction Sheet J03720 for harness wire connection is02270 Headlamp wire harness Billet headlamp shell Grommet Connector 1 2 3 4 Figure 3 Install Wiring Harness in Billet Headlamp Shell 3 See Figure 4 Install billet headlamp mount 1 to headlamp shell 2 using two 1 4 20 x 7 8 in screws 3 lockwashers 4 and locknuts 5 supplied in kit Align mount and tighten hardware until snug NOTE The wiring harness should be routed along the top of the mounting block 4 See Figure 5 Install mounting block 1 to headlamp mount assembly 2 using two 3 8 16 x 3 4 in screws 3 lock washers 4 and flat w
6. adlamp Assembly 1 Softail and Dyna Models a 2004 and earlier See Figure 7 Install gasket from kit over boot and existing gasket Position gasket according to the adapter ring wave shape or L shape cross section equipped with lens assembly b 2005 and later See Figure 8 Install gasket from kit over boot and existing gasket Position gasket according to the adapter ring wave shape or L shape cross section equipped with lens assembly VRSC Models a See Figure 8 Install gasket from kit over boot and existing gasket Position gasket according to the adapter ring L shape cross section in VRSC Bracket for Billet Headlamp Shell Kit 68211 05 NOTE The adapter ring will be installed with the outer flange facing out and positioned as described in the following step J03018 is03123 Lens and bulb Gaskets with adapter ring item 3 Adapter ring wave shape cross section Headlamp boss Gaskets with adapter ring item 6 Adapter ring L shape cross section O OT SO NS Figure 7 Install Gasket 2004 Earlier Lens Assembly 4 of 10 is03121 Lens and bulb Gaskets with adapter ring item 3 Adapter ring wave shape cross section Headlamp boss Gaskets with adapter ring item 6 Adapter ring L shape cross section SO No Figure 8 Install Gasket 2005 Later Lens Assembly See Figure 9 Install adapter ring 1 in headlamp shell 2 with lens boss cut out 3 at 3 o cloc
7. all pry bar in place of a screwdriver Small flat washers or pennies can be used as shims as each washer penny is approximately 0 060 in 1 5 mm thick The trim ring can be removed without damaging either the trim ring or headlamp shell Taping the shims in place allows one person to remove the trim ring without damaging the chrome is02281 1 Opening 2 Trim ring Figure 12 Pry Bottom of Trim Ring Away from Headlamp Shell 3 See Figure 13 Insert shim s 1 equal to approximately 0 12 in 3 mm in gap between trim ring 2 and headlamp shell 3 Tape shim s to trim ring and headlamp shell to hold them in place 4 Insert a 0 06 in 1 5 mm shim 4 into gap to the right of shims at the bottom of trim ring and slide shim in gap counterclockwise until it sticks The shim should now be J03018 at approximately the 2 or 3 o clock position Tape shim in place 5 Insert a 0 06 in 1 5 mm shim 5 into gap to the left of shims at the bottom of trim ring and slide shim in gap clockwise until it sticks The shim should now be at approximately the 9 or 10 o clock position Tape shim in place is02282 Shim 0 12 in 3 mm Trim ring Headlamp shell Right shim 0 06 in 1 5 mm Left shim 0 06 in 1 5 mm SSO Niet Figure 13 Remove Trim Ring 6 Cover tip of a small slotted screwdriver with duct tape and insert tip of screwdriver in gap between 0 06 in 1 5 mm shims 4 and
8. ashers 5 from kit Align mounting block and tighten hardware until snug 5 Softail and Dyna See Figure 6 Install headlamp shell and mounting block assembly 1 onto headlamp mounting plate lower bracket 2 using a 3 8 16 x 1 3 4 in screw 3 from kit and lockwasher 4 previously removed Align shell and mounting block and tighten screw to 31 ft lbs 42 Nm VRSC Refer to Instruction Sheet J03720 to install head lamp shell and mounting block onto lower triple clamp J03018 is02271 Billet headlamp mount Headlamp shell Screw 2 Lockwasher 2 5 Locknut 2 PN Figure 4 Install Headlamp Mount to Headlamp Shell is02272 Mounting block Headlamp mount assembly Screw 2 Lockwasher 2 Flat washer 2 oa oN Figure 5 Install Billet Headlamp Mounting Block on Headlamp Mount Assembly 3 of 10 is02273 1 Headlamp shell and mounting block assembly 2 Headlamp mounting plate lower bracket 3 Screw 4 Lockwasher Figure 6 Install Headlamp Shell and Mounting Block 6 See Figure 4 Tighten 1 4 in hardware previously installed to 108 in Ibs 12 Nm 7 See Figure 5 Place a protective covering between top of headlamp shell and bottom of upper bracket Softail and Dyna or top triple clamp VRSC not shown Tilt head lamp shell back until it just misses bottom of upper bracket top triple clamp Tighten screw 3 to 31 ft lbs 42 Nm He
9. cMOTOR HARLEY DAVIDSON WY J03018 INSTRUCTIONS REV 2007 07 22 BILLET HEADLAMP SHELL GENERAL Kit Number 67704 03 Models For model fitment information please see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required WARNING 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 Proper installation of this kit requires the use of Snap on Pick Tool TT600 3 and a silicone based lubricant which can be purchased at a Harley Davidson dealer Kit Contents See Figure 15 and Table 3 REMOVAL Softail and Dyna Models 1 Remove the windshield if equipped 2 Remove the seat according to the procedure in the applicable Service Manual WARNING To prevent spray of fuel purge system of high pressure fuel before supply line is disconnected Gasoline is extremely flammable and highly explosive which could result in death or serious injury
10. d center NOTE Do not use a petroleum based lubricant on the trim ring O ring Petroleum based lubricants will make the O ring swell and make the headlamp difficult to disassemble 6 Apply a light coat of silicone based lubricant or soap if a silicone lubricant is not available on the O ring 5 surface This will aid in disassembly of headlamp when servicing at a later date 7 Install O ring 5 over groove in trim ring 6 Softail and Dyna Models WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 1 Connect battery cables positive cable first WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 2 Install seat according to the instructions in the Service Manual w Align headlamp as described in the alignment procedure in the applicable Service Manual Tighten headlamp mounting hardware to 31 ft lbs 42 Nm NOTE Do not use a petroleum based lubricant on the trim ring O ring Petroleum based lubricants will make the O ring swell and make the headlamp difficult to disassemble 4 See Figure 10 Install trim ring 6 with O ring 5 into headlamp shell 2 Use a s
11. er ring wave shape or L shape cross section equipped with lens assembly VRSC Models a See Figure 8 Install gasket from kit over boot and existing gasket Position gasket according to the adapter ring L shape cross section in VRSC Bracket for Billet Headlamp Shell Kit 68211 05 NOTE The adapter ring will be installed with the outer flange facing out and positioned as described in the following step 2 See Figure 9 Install adapter ring 1 in headlamp shell 2 with lens boss cut out 3 at 3 o clock position and shell boss cut out 4 at 8 o clock position VRSC models use adapter ring from Billet Headlamp Shell Kit 6821 1 05 3 Install 3 prong connector 5 onto rear of lens assembly NOTE When installing the lens assembly into the shell make sure the wiring harness grommet is seated in the hole in the shell 4 Install lens assembly 6 into headlamp shell 2 aligning headlamp boss 7 with lens boss cut out 3 on adapter ring The headlamp gasket tabs should be sandwiched between the outside diameter of the lens assembly and the adapter ring 5 See Figure 10 Snap retaining ring 1 from kit into groove in headlamp shell 2 It may be necessary to use a needle nose pliers for leverage to install retaining ring The J03018 retainer should push up against front of lens Position retainer so it does not hit headlamp bosses 3 on front of lens Gap 4 in retaining ring should be positioned at bottom dea
12. ield if equipped See Trim Windshield in this Instruction Sheet 5 Install windshield if equipped Refer to appropriate Instruction Sheet for procedures 6 of 10 TRIM WINDSHIELD Table 1 FXST FXSTB FXDWG Windshield Windshield Part Number Description Amount to Trim 1 Rigid Windshields 91820 85A Sport Windshield Fits as is None 58025 91B Compact Windshield Higher Position Fits as is None 58059 93A Trim as desired to a maximum of 1 in 25 mm Detachable Windshields Using Docking Kit 58350 96 58340 96 Compact Windshield Fits as is None 58627 99 58341 96 57965 97A Super Sport Windshield 5 16 in 8 mm Table 2 FXSTD Windshield Windshield Part Number Description Amount to Trim 1 Detachable Windshields Using Docking Kit 58397 00 57090 00A Compact Windshield 1 1 4 to 1 1 2 in 82 to 38 mm 57824 00A 57837 00A Super Sport Windshield 1 1 4 to 1 1 2 in 32 to 38 mm NOTE This section applies to Softail and Dyna models It does not apply to VRSC models This procedure explains how to trim a Harley Davidson wind shield in order to gain needed clearance for the new headlamp shell Refer to the appropriate chart for your model motorcycle and windshield type to determine the amount that your wind shield may need to be trimmed 1 See Figure 11 Cover an area extending approximately 2 in 50 mm from windshield headlamp opening with
13. ilicone based lubricant or soap if a silicone lubricant is not available on the O ring outer diameter to ease installation VRSC Models 1 Install right side cover and maxi fuse Refer to MAXI FUSE in Service Manual N Align headlamp as described in the alignment procedure in the applicable Service Manual Tighten headlamp mounting hardware to 31 ft lbs 42 Nm NOTE Do not use a petroleum based lubricant on the trim ring O ring Petroleum based lubricants will make the O ring swell and make the headlamp difficult to disassemble 3 See Figure 10 Install trim ring 6 with O ring 5 into headlamp shell 2 Use a silicone based lubricant or soap if a silicone lubricant is not available on the O ring outer diameter to ease installation 9 of 10 SERVICE PARTS is03112 Figure 15 Service Parts Billet Headlamp Shell Table 3 Service Parts Billet Headlamp Shell ltem Description Quantity Part Item Description Quantity Part Number Number 1 Screw hex socket button 1 4 20 x 7 8 94387 92T 9 O ring 11385 in 2 Lockwasher 2 94080 90T 10 Retaining ring 67706 03 Locknut 1 4 20 2 7686 11 Trim ring 67709 03 Screw hex socket button 3 8 16 x 3 4 94399 92T 12 Shell billet headlamp Not Sold in 2 Separately Lockwasher 3 8 in 2 94082 90T Mount kit 67754 03 Washer flat chrome 3 8 in 2 94067 90T 13 e Mount Not Sold Separately 7 Sc
14. k position and shell boss cut out 4 at 8 o clock position VRSC models use adapter ring from Billet Headlamp Shell Kit 68211 05 Install 3 prong connector 5 onto rear of lens assembly NOTE When installing the lens assembly into the shell make sure the wiring harness grommet is seated in the hole in the shell 4 Install lens assembly 6 into headlamp shell 2 aligning headlamp boss 7 with lens boss cut out 3 on adapter ring The headlamp gasket tabs should be sandwiched between the outside diameter of the lens assembly and the adapter ring See Figure 10 Snap retaining ring 1 from kit into groove in headlamp shell 2 It may be necessary to use a needle nose pliers for leverage to install retaining ring The retainer should push up against front of lens Position retainer so it does not hit headlamp bosses 3 on front of lens Gap in retaining ring 4 should be positioned at bottom dead center J03018 is03122 Adapter ring L shape cross section shown Headlamp shell Lens boss cut out Shell boss cut out 3 prong connector Lens assembly includes gaskets and boot Headlamp boss 1 2 3 4 5 6 7 Figure 9 Install Lens Assembly is02275 Retaining ring Headlamp shell Headlamp bosses Gap in retaining ring O ring Trim ring DOL aO N E Figure 10 Install Trim Ring NOTE Do not use a petroleum based lubricant on the trim ring O ring Petroleum based
15. lubricants will make the O ring swell and make the headlamp difficult to disassemble 6 Apply a light coat of silicone based lubricant or soap if a silicone lubricant is not available on the O ring 5 surface This will aid in disassembly of headlamp when servicing at a later date Install O ring 5 over groove in trim ring 6 Connect headlamp connector to vehicle wire harness 5 of 10 Softail and Dyna Models PINT N IN Stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002a NOTE Be sure that wiring harness does not get pinched between fuel tank and frame during tank installation FXST B D models Install fuel tank Refer to FUEL TANK CARBURETED or FUEL TANK EFI in Service Manual FXDWG models Install fuel tank Refer to FUEL TANK in Service Manual e WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 2 Connect battery cables positive cable first WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious inj
16. rew hex socket head 3 8 16 x 1 3 4 94357 91T 14 e Mounting block Not Sold in not shown Separately 8 Gasket 67601 94A J03018 10 of 10
17. ury 00070b 3 Install seat according to the instructions in the Service Manual J03018 4 Align headlamp as described in the alignment procedure in the applicable Service Manual Tighten headlamp mounting hardware to 31 ft lbs 42 Nm NOTE Do not use a petroleum based lubricant on the trim ring O ring Petroleum based lubricants will make the O ring swell and make the headlamp difficult to disassemble 5 See Figure 10 Install trim ring 6 with O ring 5 into headlamp shell 2 Use a silicone based lubricant or soap if a silicone lubricant is not available on the O ring outer diameter to ease installation 6 Trim windshield if equipped See Trim Windshield in this Instruction Sheet 7 Install windshield if equipped Refer to appropriate Instruction Sheet for procedures VRSC Models 1 Install right side cover and maxi fuse Refer to MAXI FUSE in Service Manual 2 Align headlamp as described in the alignment procedure in the applicable Service Manual Tighten headlamp mounting hardware to 31 ft lbs 42 Nm NOTE Do not use a petroleum based lubricant on the trim ring O ring Petroleum based lubricants will make the O ring swell and make the headlamp difficult to disassemble 3 See Figure 10 Install trim ring 6 with O ring 5 into headlamp shell 2 Use a silicone based lubricant or soap if a silicone lubricant is not available on the O ring outer diameter to ease installation 4 Trim windsh
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