Home

freight train chrome or gloss black headlight - Harley

1. blue jaws of the Packard Crimp Tool 388125 8 Feed the stripped lead s up to the wire stop inside the metal insert in one half of the connector Squeeze the tool to crimp the metal insert The tool automatically opens when finished Repeat for the other end of the connector to capture one or two stripped leads including if required the fuse block adapter 3 of 7 13 Splice headlamp harness into existing wires cut in Step 6 as follows a Strip 3 8 inch 9 524 mm of insulation off each wire end to be spliced b Insert each end of the wires to be spliced into opposite ends of a butt splice connector c Using an H D 38125 8 crimping tool crimp the wire ends into the connector d Using the UltraTorch UT 100 39969 or other suitable radiant heating device heat the crimped splice from the center of the crimp out to each end until the sealant exudes out both ends of the connector and the tubing assumes a smooth cylindrical appearance 14 See Figure 10 Fasten the brake line on the back of the right hand nacelle piece using the two brake line retaining clamps 16 from the kit Attach the retaining clamps to the right hand nacelle piece using the original 5 8 inch long capscrews 1 4 flat washers 1 and locknuts 5 washer goes under nut 15 See Figure 6 Install the previously removed headlamp assembly 8 into the headlamp bucket 6 using the new retaining ring 7 and three screws 3 16 Connect the headlamp
2. 3 Nm J04200 12 See Figure 10 Install well nuts 10 into holes in nacelle halves Install right side of nacelle 7 as follows a Loosely attach the bottom hole of the nacelle to the fork bracket with a 5 8 inch long screw 14 lock washer 12 and flat washer 2 on both the inside and outside of the nacelle Placing a flat washer on each side of the nacelle will space the nacelle out to be flush with the fork slider covers b Attach the top hole of the nacelle with a 7 8 inch long screw 15 lock washer 12 and flat washer 2 all on the outside of the nacelle Screw must not bottom out in hole Do not tighten screws at this time c Repeat for left side nacelle Figure 5 Splice 1 into 1 Sequence WARNING Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a e Avoid directing the heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed e Always keep hands away from tool tip area and heat shrink attachment NOTE See Figure 5 Gently hold the butt splice from the kit in the
3. mm from the existing headlamp contour as shown in Figure 9 The new cut is shown in Figure 9 as a dashed line 1 Using a saber saw with a fine tooth blade carefully cut the new contour on the windshield Clean the edges of the cut with a fine grit grinding wheel 5 of 7 SERVICE PARTS Figure 10 Service Parts for Chrome and Gloss Black Headlight Nacelle Kits Table 1 Service Parts Table Item Description Quantity Part Number Item Description Quantity Part Number 1 Flat washer chrome 2 94065 90T 15 Screw button head hex socket 2 94467 94T 2 Flat washer chrome 6 94066 90T 16 Clamp 2 41713 86 3 Connector headlamp 68816 96 17 Butt connector 3 70586 93 4 Handlebar clamp cover chrome 67992 07 Headlamp mounting assembly 67991 07 Handlebar clamp cover black 61300142 5 Locknut 2 7686 18 Adjusting screw headlamp 67724 71 Screw pan head 8 2806 19 Headlamp bucket assembly 67728 02 7 Nacelle left side chrome 67916 96A 20 Mounting ring headlamp 67732 71B Nacelle left side black 61300139 8 Nacelle right side chrome 67908 96A 21 Ring assembly retainer 67726 71A Nacelle right side black 61300140 9 Washer 8 6717 22 Spring headlamp trim ring top 67778 60 10 Well nut 8 5210 23 Spring headlamp trim ring bottom 67780 60 2 11 Lockwasher 2 94080 90T 24 Headlamp trim ring chrome 67712 83 Headlamp trim
4. ring black 67700182 12 Lockwasher 4 94081 90T 25 Screw headlamp trim ring 67718 60A 13 Screw button head hex socket 2 94385 92T 26 Screw retaining ring 3 67721 48 14 Screw button head hex socket 2 94396 92T Screw button head hex socket 2 94468 94T J04200 6 of 7 Table 1 Service Parts Table Item Description Quantity Part Number Item Description Quantity Part Number Items Mentioned in Text But Not Included in Kit A Boot headlamp E Envelope headlamp B Wire retaining clip F Screw 2 C Bulb headlamp Bulb position D Shield bulb J04200 7 of7
5. 51b 1 Refer to the service manual and follow the instructions given to remove the main fuse For ALL models WITHOUT main fuse J04200 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING 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 black battery cable from the negative battery terminal Retain all seat mounting hardware 2 Cover the gas tank to protect tank during installation Trim ring Retaining ring Headlamp assembly Mounting block Lamp housing 1 2 3 4 5 Figure 1 Headlamp Assembly 1 of 7 Please dispose of materials responsibly is03411 Front panel Right side panel Left side panel Trim strip 2 Upper fork bracket a a ET Figure 2 Front Fork Panels See Figure 1 Remove trim ring screw and trim ring 1 Remove three retaining ring screws and retaining ring 2 from headlamp assembly 3 Pull lamp bulb out of con nector NOTE Be careful not to damage the headlamp assembly when removing it from the headlamp housing 5 Disconnect headlamp harness from headlamp housing assembly Also if the headlamp assembly is equipped with a position bulb disconnect the two sp
6. ade connectors from it Remove headlamp assembly NOTE Be careful not to damage the headlamp assembly when removing 6 Cut the headlamp wires directly behind the headlamp connector Remove screw washers lock washer hex nut and head lamp housing from mounting block See Figure 2 After headlamp housing is removed remove screws that hold trim strips 4 side back panels 2 amp 3 and front panel 1 in place and remove panels When removing panels carefully remove the brake line routing clamps from the right side back panel Do not open the brake line See Figure 1 Remove the mounting block 4 and mounting block hardware J04200 is03416 1 Screw 4 2 Riser cap 2 3 Riser 2 Figure 3 Riser Orientation FLSTF 10 2007 and later FLSTF only Replace handlebar risers with Handlebar Riser Kit 56789 05 as follows a Refer to the appropriate service manual and remove the upper handlebar clamp and risers After removing the upper clamp move the assembled handlebar aside as necessary in order to remove risers b See Figure 3 Loosely install new risers Kit Number 56789 05 oriented as shown to the upper triple tree using the stock screws lock washers and washers Install ground cable and internal tooth lock washer onto the right side riser screw c Using the knurled areas of the handlebar as a guide center the handlebar on the risers d Install two riser caps 2 onto the risers over t
7. cMOTOR HARLEY DAVIDSON WY J04200 INSTRUCTIONS REV 2012 05 09 FREIGHT TRAIN CHROME OR GLOSS BLACK HEADLIGHT NACELLE KITS GENERAL Kit Number 67907 96C 61300138 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required For 2007 and later FLSTF installation requires the separate purchase and installation of Handlebar Riser Kit 56789 05 For 2009 and later FLSTC installation requires the separate purchase and installation of Handlebar Riser Kit 46809 09 Hardware Kit 67897 96B when installed with windshield and or passing lamps IWIN NIN 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 See Figure 10 and Table 1 INSTALLATION For ALL models WITH main fuse WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 002
8. harness to the headlamp and bucket assembly Also if the headlamp assembly is equipped with a position bulb connect the two spade connectors to it 17 Install the headlamp and bucket assembly into the nacelle using eight washers 4 and screws 5 from the kit 18 See Figure 10 Place handlebar cover 4 into position and secure with 5 8 inch long screws 13 and lock washers 11 is03436 Nacelle Well nut 8 Screw 3 Washer 8 Screw 8 Headlamp bucket assembly Retaining ring Headlamp assembly ONS OPO Nos Headlamp trim ring Figure 6 Install Headlamp J04200 19 Tighten all 5 16 inch screws to 19 ft lbs 25 Nm Tighten headlamp screws and handlebar cover screws snugly 20 Models WITHOUT main fuse Connect the battery neg ative cable Refer to BATTERY CABLES in the service manual Models WITH main fuse Refer to the service manual and follow the instructions given to install the main fuse WARNING Be sure headlamp tail and stop lamp and turn signals are operating properly before riding Poor visibility of rider to other motorists can result in death or serious injury 00478b 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 21 Refer to the appropriate service manual and install seat 22 Align the headlam
9. he handlebar using four screws 1 included in the kit e Verify the gaps between the risers and riser caps at the front and rear of the handlebars are approximately even Tighten the riser cap screws to 12 15 ft lbs 16 3 20 3 Nm f Tighten the risers mounting screws to 30 40 ft lbs 40 7 54 3 Nm 2 of 7 is05702 Lower right clamp Lower left clamp Upper clamp Pe NS Screws 4 Figure 4 Riser Orientation FLSTC 11 2009 and later FLSTC only Replace handlebar risers with Handlebar Riser Kit 46809 09 as follows a Refer to the appropriate service manual and remove the upper handlebar clamp and risers After removing the upper clamp move the assembled handlebar aside as necessary in order to remove risers b See Figure 4 Loosely install new risers Kit Number 46809 09 oriented as shown to the upper triple tree using the stock screws lock washers and washers Install ground cable and internal tooth lock washer onto the right side riser screw c Using the knurled areas of the handlebar as a guide center the handlebar on the risers d Install riser cap 3 onto the risers 1 and 2 over the handlebar using four screws 4 included in the kit e Verify the gaps between the risers and riser caps at the front and rear of the handlebars are approximately even Tighten the riser cap screws to 12 16 ft lbs 16 3 21 7 Nm f Tighten the risers mounting screws to 30 40 ft lbs 40 7 54
10. p according to the Headlamp Adjustment procedure below 23 Install headlamp trim ring 24 and headlamp trim ring screw 25 24 If equipped trim the detachable windshield according to the Trimming a Detachable Windshield procedure below Headlamp Adjustment 1 See the Owner s Manual Verify correct front and rear tire inflation pressure is03439 1 Level with Center of Headlamp 2 25 feet 7 6 meters Figure 7 Headlamp Adjustment 2 Place motorcycle on level floor or pavement in an area with minimum light 3 See Figure 7 Position the motorcycle 25 ft 7 6 m away from a screen or wall Measure the distance from directly below the front axle to the base of the wall or screen 4 Draw a horizontal on the screen or wall 35 inch 0 9 m above the floor 5 Load the vehicle with rider passenger if normally present and any cargo normally carried Weight will compress the vehicle suspension slightly 40f7 6 Stand the motorcycle upright with both tires resting on the floor and with front wheel held in straight alignment dir ectly forward 7 Turn the ignition headlamp switch to IGNITION position Set handlebar headlamp switch to HIGH beam position 8 Check and the light beam for proper adjustment a The main beam of light broad flat pattern of light should be centered equally above and below the horizontal line on the screen or wall b The main beam of the light should be direc
11. ted straight ahead Properly adjusted headlamps project an equal area of light to the left and right of center 9 If necessary adjust the headlamp beam as follows a See Figure 8 Raise or lower the headlamp beam as necessary by turning the vertical adjusting screw 1 Turn the screw clockwise to raise the beam or coun terclockwise to lower the beam b See Figure 8 Adjust the headlamp beam left or right as necessary by turning the horizontal adjusting screw 2 Turn the screw clockwise to adjust the beam towards the right side of the motorcycle or counterclockwise to adjust the beam towards the left side of the motorcycle 10 Turn the ignition neadlamp switch to OFF position Trimming a Detachable Windshield This procedure explains how to trim a Harley Davidson detachable windshield to fit the nacelle d is00114 1 Vertical adjustment screw 2 Horizontal adjustment screw is03422 1 Cut new contour 2 Existing windshield contour 3 Trim ring mounting grommet 2 Figure 8 Headlamp Adjustment J04200 Figure 9 Trimming Detachable Windshield See Figure 9 Cover the bottom 2 inches of windshield closest to the headlamp contour on both sides of the windshield with two layers of masking tape This tape provides a surface on which to mark the new cut as well as keep the cut neat during cutting Mark the new cut location alongside and approximately 1 1 4 inches 831 75

freight train chrome or gloss black headlight - Harley

Contents

Download Pdf Manuals

Related Search

Related Contents