NACELLE AND HANDLEBAR COVER KIT
J026412009-07-10
GENERAL
Kit Number
46547-03A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
WARNINGRider and passenger safety depend 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. (00333b)
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.
Special Tools Required
A Pozidrive screwdriver is required for proper installation of this kit.
REMOVAL
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
WARNINGDisconnect negative (-) 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. (00049a)
- Remove the seat and disconnect the battery cables, negative cable first. Follow the instructions in the service manual.
Remove the Windshield
- See Figure 1. Raise the wireform latch springs (1) on each side of the windshield.
- Stand in front of the vehicle and gently pull the top of the windshield until the upper notches on the side brackets are free of the upper grommets (3).
- Carefully raise the windshield until the lower notches in the side brackets are free of the lower grommets.
- Remove the windshield and set aside.
Remove the Nacelle
- See Figure 2. Remove self-tapping screw (19) at the bottom of the trim ring (1). Remove the trim ring.
- Remove the eight black screws (17) to free the headlamp assembly (18) from the nacelle (3). Remove the eight well nuts (16) from the nacelle. Save hardware for installation.
- Squeeze the two external tabs (if equipped) on the back of the headlamp bulb to remove the wire connector from the bulb. Remove the headlamp bulb assembly.
- Remove the flange nut (2) to release the trim strip (6) at the top of the nacelle. Discard trim strip.
- Carefully pry off the fork lock trim (10) from the handlebar cover (7) to access the two Pozidrive screws (9). Remove the screws and save for installation.
- Loosen, but do not remove Pozidrive screw (8) from the front of the handlebar cover.
- Remove the four chrome acorn nuts from the left and right fork studs.
- Protect the front fender with clean shop cloths or other suitable material.
- Remove the passing lamps and bracket from the left and right fork studs and carefully set the assembly on the front fender.
- Remove the windshield grommets and clutch cable clamp from the left and right fork studs.
- Raise the handlebar cover slight and separate the halves of the headlamp nacelle while removing the handlebar cover.
- Carefully remove one side of the headlamp nacelle from the fork studs and pull the pin and socket halves of the 4-place switch connector apart. Repeat for the other side.
- Remove the trim pieces (11) from the nacelle. Remove the boot (12) and disassemble the toggle switches (14). Save the trim pieces, switches and boots for installation. Discard the nacelle halves including the switch labels (13).
NOTE
Earlier models used a stamped metal speed nut instead of a flange nut to fasten the nacelle trim.
| 1 | Wireform Latch Spring |
| 2 | Headlamp Nacelle |
| 3 | Upper Grommet |
| 4 | Passing Lamp Support |
Figure 1. Remove and Install the Windshield (Left Side Shown)
INSTALLATION
Install Headlamp Nacelle
| 1. | For HDI Models: See Figure 2. Install new ON-OFF label (13) around the switch mounting hole on the left nacelle half. Install the fog lamp label (13) around the switch mounting hole on the right nacelle half. For DOM Models: See Figure 2. Install new ON-OFF labels (13) around the switch mounting holes on the two nacelle halves. NOTE The accessory and passing lamp switches are identical. | |
| 2. | Insert a stock switch (14) into the mounting hole from the inside of the nacelle making sure the groove in the switch collar engages the notch in the hole. Install the boot (12) onto the collar and tighten securely. | |
| 3. | Install a trim piece (11) over the rear flange of the nacelle half. Repeat for the other nacelle half. | |
| 4. | Assemble the halves of the nacelle halves together on the vehicle, engaging the holes in the nacelle with the left and right fork studs. Connect the pin and socket halves of the accessory switch 4-place connector securely. Repeat for the passing lamp switch connector. | |
| 5. | Remove the Pozidrive screw (8), nut (4) and flat washer (5) from the handlebar cover (7) (removed earlier). Discard the handlebar cover and nut. | |
| 6. | Loosely assemble screw (8) and flat washer with screw (see Figure 3 , item 5) to the new handlebar cover (see Figure 3 , item 4). | |
| 7. | Slightly spread the headlamp nacelle halves and install the nut and flat washer on the handlebar cover from inside the nacelle. Install the Pozidrive screw (8) and position the cover over the flange at the top of the nacelle halves. Bring the nacelle halves together then tighten the screw to 1.1–2.3 N·m (10–20 in-lbs). | |
| 8. | Install the two Pozidrive screws (9) to secure the handlebar cover to the fork lock mechanism. Install the fork lock trim (10). | |
| 9. | Insert the weld stud of the trim strip (6) into the hole at the top of the nacelle. From the inside of the nacelle and install the flange nut (2). Tighten the flange nut to 1.7–2.3 N·m (15–20 in-lbs). | |
| 10. | Install the four windshield grommets on the left and right fork studs. Slide the passing lamp and bracket assembly onto the fork studs. Verify that the four grommets are in place on the inboard side of the passing lamp brackets. | |
| 11. | Install the clutch cable clamp and cable on the upper left stud. Thread the acorn nuts onto the fork studs and tighten to 8.1–12.2 N·m (72–108 in-lbs). | |
| 12. | Install the eight well nuts (16) (removed earlier). Attach the wire connector to the back of the headlamp bulb. | |
| 13. | Align the holes in the headlamp housing (18) and nacelle. Install eight screws (17) and tighten securely. | |
| 14. | Install the trim ring (1) with the self-tapping screw (19). Tighten securely. |
Install Windshield
NOTE
Verify that the notches on each bracket of the windshield are firmly seated on a rubber grommet to avoid scratching the headlamp nacelle or passing lamp support.
- See Figure 1. Lower the windshield into position and carefully insert the side brackets between the headlamp nacelle (2) and the passing lamp supports (4) until the bottom notches are firmly seated on the lower grommets.
- Stand in front of the vehicle and gently push the top of the windshield toward the rear until the upper notches fully engage the upper grommets (3).
- Push down on the wireform latch springs so they overhang the rubber grommets. If adjustment is necessary, loosen the retaining bolts and rotate the latch springs into proper position.
Final Assembly
WARNINGConnect 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 the battery cables, positive (+) cable first following the instructions in the service manual. | |
| 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 the seat following the instructions in the service manual. |
| 1 | Trim ring |
| 2 | Flange nut (speed nut on some models) |
| 3 | Headlamp nacelle (left side shown) |
| 4 | Nut with lockwasher |
| 5 | Flat washer |
| 6 | Upper nacelle trim |
| 7 | Handlebar cover |
| 8 | Screw, pan head, Pozidrive |
| 9 | Screw, flat head, Pozidrive (2) |
| 10 | Fork lock trim |
| 11 | Rear nacelle trim (2) |
| 12 | Switch boot (2) |
| 13 | Label, ON-OFF (2) (DOM only), Label, ON-OFF and Fog Lamp (HDI only) |
| 14 | Toggle switch (2) |
| 15 | Wireform clip |
| 16 | Well nut (8) |
| 17 | Screw, black (8) |
| 18 | Headlamp assembly |
| 19 | Screw, self-tapping |
Figure 2. Remove and Install Nacelle and Handlebar Cover
SERVICE PARTS
Figure 3. Service Parts: Nacelle and Handlebar Cover Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Nacelle half, left | 67911-03B |
2 | Nacelle half, right (not shown) | 67912-03C |
3 | Trim, Nacelle | 46554-03 |
4 | Cover, handlebar | 46553-03 |
5 | Nut, flange | 7888A |
6 | Label, ON-OFF (2) (discard one for HDI installation) | 14019-83A |
7 | Label, fog lamp (for HDI installation only) | 15346-98A |