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5-3/4 INCH HEADLAMP HOUSING
J054042016-07-18
GENERAL
Kit Number
67700093
Models
This kit is needed in order to allow the installation of a 5-3/4 inch (14.6 cm) LED headlamp (Part Nos. 73273-11 or 67700043) on specific model motorcycles. For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Service Manual Required
WARNING
Rider 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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 1 and Table 1.
INSTALLATION
NOTE
For 2007 and later vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1. Follow service manual instructions to loosen the fuel tank.
2. Separate four-way headlamp harness socket housing [38B] from main harness pin housing [38A].
3. Remove and retain the fasteners for the headlamp housing, and remove the headlamp assembly from the mount block.
4. Disassemble the headlamp assembly. Discard the lamp assembly, headlamp shell assembly, and chrome trim ring.
5. See Figure 1. Install the bumpers (3 and 4) from the kit onto the leading edge (A) of the mounting bracket inside the new black headlamp housing (1) as shown.
NOTE
When assembling headlamp, make sure slots and tabs in headlamp, retainer ring and bezel are aligned.
6. Position the retainer ring (2) into the front face of the headlamp housing in the orientation shown, and press firmly into place.
7. Mate the connector (B) inside the headlamp housing with the connector on the new LED headlamp (C, purchased separately).
NOTE
To enable the headlamp to seat properly on the retainer ring, the connector must be positioned at the rear of the headlamp housing, toward the lower right (lower left when looking into the housing).
8. Position the connector inside the headlamp housing near point (D), and insert the headlamp into the housing. Adjust the position of the connector as necessary to seat the lamp flat against the retainer ring.
9. Install the new black bezel (5) over the front of the headlamp housing, and fasten with the new Phillips head screw (6) from the kit. Tighten to 0.5–0.9 N·m (5–8 in-lbs).
10. Attach the headlamp assembly to the mount block using the fasteners removed earlier. Tighten enough to hold in position.
11. Connect the four-way headlamp harness socket housing [38B] to main harness pin housing [38A] until it clicks into place.
12. Follow service manual instructions to tighten the fuel tank.
NOTE
Verify that the ignition key switch is in the OFF position before installing the main fuse.
13. Refer to the service manual and follow the instructions to install the main fuse.
14. Test the headlamp for proper operation.
15. Adjust the headlamp alignment per service manual instructions, then tighten the headlamp mounting fasteners to 33.9–40.7 N·m (25–30 ft-lbs).
SERVICE PARTS
Figure 1. Service Parts, 5-3/4 Inch Headlamp Housing
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Headlamp housing (black)
Not sold separately
2
Retainer ring
67769-93
3
Bumper, lower
Not sold separately
4
Bumper, upper
Not sold separately
5
Bezel (black)
69925-08
6
Screw, Phillips head, #8-32
Not sold separately
Items mentioned in text, but not included in kit.
A
Leading edge of mounting bracket inside headlamp housing
B
Connector inside headlamp housing
C
LED headlamp
D
Position of connector inside headlamp housing