FREIGHT TRAIN CHROME OR GLOSS BLACK HEADLIGHT NACELLE KITS
J042002013-01-28
GENERAL
Kit Number
67907-96C, 61300138
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
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.
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.
INSTALLATION
For ALL models, WITH main fuse:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the service manual and follow the instructions given to remove the main fuse.
For ALL models, WITHOUT main fuse:
WARNINGTo 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. | 
Figure 1. Headlamp Assembly 
Figure 2. Front Fork Panels | ||||||||||||||||||||
| 3. | See Figure 1. Remove trim ring screw and trim ring (1). | |||||||||||||||||||||
| 4. | Remove three retaining ring screws and retaining ring (2) from headlamp assembly (3). Pull lamp bulb out of connector. 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 spade 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. | |||||||||||||||||||||
| 7. | Remove screw, washers, lock washer, hex nut and headlamp housing from mounting block. | |||||||||||||||||||||
| 8. | See Figure 2. After headlamp housing is removed, remove screws that hold trim strips (4), side back panels (2 & 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. | |||||||||||||||||||||
| 9. | See Figure 1. Remove the mounting block (4) and mounting block hardware. | 
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 the 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 16.3–20.3 N·m (12–15 ft-lbs). f. Tighten the risers mounting screws to 40.7–54.3 N·m (30–40 ft-lbs). | 
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 16.3–21.7 N·m (12–16 ft-lbs). f. Tighten the risers mounting screws to 40.7–54.3 N·m (30–40 ft-lbs). | |||||||||||||||||||||
| 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
WARNINGBe 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)
- Avoid directing the heat toward any fuel system component. Extreme heat can cause fuel ignition/ explosion resulting in death or serious injury.
- Avoid directing heat toward any electrical system component other than the connectors on which heat-shrink work is being performed.
- 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 "blue" jaws of the Packard Crimp Tool (38125-8). 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.
| 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 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). | 
Figure 6. Install Headlamp | ||||||||||||||||||
| 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 negative (-) 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) WARNINGAfter 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 headlamp 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. | 
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. | |||||
| 6. | Stand the motorcycle upright with both tires resting on the floor and with front wheel held in straight alignment (directly 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 directed 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 counterclockwise 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/headlamp switch to OFF position. |
Trimming a Detachable Windshield
This procedure explains how to trim a Harley-Davidson detachable windshield to fit the nacelle.
| 1 | Vertical adjustment screw |
| 2 | Horizontal adjustment screw |
| 3 | Trim ring mounting grommet (2) |
Figure 8. Headlamp Adjustment
| 1 | Cut new contour |
| 2 | Existing windshield contour |
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.
- 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.
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 Handlebar clamp cover, black | 67992-07 61300142 | Headlamp mounting assembly | Not Sold Separately | ||
5 | Locknut (2) | 7686 | 18 |
| 67724-71 | |
6 | Screw, pan head (8) | 2806 | 19 |
| 67728-02 | |
7 | Nacelle, left side, chrome Nacelle, left side, black | 67916-96A 61300139 | 20 |
| 67732-71B | |
8 | Nacelle, right side, chrome Nacelle, right side, black | 67908-96A 61300140 | 21 |
| 67726-71A | |
9 | Washer (8) | 6717 | 22 |
| 67778-60 | |
10 | Well nut (8) | 5210 | 23 |
| 67780-60 | |
11 | Lockwasher (2) | 94080-90T | 24 |
| 67712-83 67700182 | |
12 | Lockwasher (4) | 94081-90T | 25 |
| 67718-60A | |
13 | Screw, button head, hex socket (2) | 94385-92T | 26 |
| 67721-48 | |
14 | Screw, button head, hex socket (2) | 94396-92T | ||||
Screw, button head, hex socket (2) | 94468-94T | |||||
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 | G | Bulb, position | |||
D | Shield, bulb | |||||