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CUSTOM AUXILIARY FORWARD LIGHTING KITS
J057652013-07-12
GENERAL
Kit Numbers
67800366, 67800367
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
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. One is available from a Harley-Davidson dealer.
ELECTRICAL OVERLOAD
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
WARNING
When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
This kit requires up to 10 amps more current from the electrical system.
Kit Contents
See Figure 4 and Table 1.
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
  • For vehicles equipped with security siren: With security fob present, turn ignition switch ON. After system is disarmed, turn ignition switch OFF. IMMEDIATELY remove the main fuse per the service manual.
  • For vehicles WITHOUT security siren: See the service manual to remove the main fuse.
  1. Remove the original equipment (OE) left and right turn signal bars per service manual instructions. Remove and retain the turn signal lenses and bulbs (see Figure 4 , Items A and B), and the acorn nuts (C) for later assembly. Discard the remaining turn signal components.
    2. NOTE
    Mark all wires before removal to aid in proper installation.
  2. Disconnect the left and right turn signal connectors per the service manual.
  3. See the service manual to position turn signal connectors and auxiliary lamp connectors for auxiliary lamp kit installation.
Auxiliary Lamp Assembly
NOTE
The Auxiliary Lamp Kit requires partial assembly before installation to the vehicle.
1. See Figure 1. Get a lamp bar (1), lamp housing (3), rubber isolator (4), clamp block (5), lockwasher (6), and locknut (7) from the kit. Install the lamp housing into the lamp bar. Fasten with the lockwasher and locknut. Tighten to 19–24 N·m (14–18 ft-lbs). Assemble the remaining lamp bar in the same way.
1Lamp bar
2Nest ring
3Auxiliary lamp housing
4Rubber isolator
5Clamp block
6Lockwasher, internal tooth
7Lock nut with nylon insert
8Turn signal standoff
9TORX head screw (2)
10Washer (2)
11Turn signal assembly (2)
12Acorn nut (4)
Figure 1. Auxiliary Lamp Assembly (Wiring Not Shown)
1Auxiliary lamp housing
2Socket housing
Figure 2. Lamp Wiring Routing Shown
2. See Figure 2. Chrome auxiliary lamp housings: Insert the terminated end of the gray/black wire through the hole in the mounting stud on the lamp housing (1). Black auxiliary lamp housings: Insert the terminated end of the gray/black wire and the bare ends of the black wires through the hole in the mounting stud on the lamp housing (1). ALL housings: Route the wiring through both larger internal passages in the lamp bracket until the knot inside the auxiliary lamp housing bottoms in the housing (1).
3. See Figure 4. Get a turn signal sub-assembly (11), turn signal stand off (8), hex socket head screw (9) and lockwasher (10) from the kit. Install the bulb and lens removed from the OE turn signal into the turn signal sub-assembly.
4. Install the new turn signal assembly to the standoff by routing the wires through the standoff, into the internal passages in the lamp bracket alongside the gray/black wire.
5. Slide the turn signal and auxiliary lamp wiring through the internal passages of the auxiliary lamp bar. Secure the turn signal assembly with the lockwasher and hex socket head screw. Tighten to 10.8–13.6 N·m (96–120 in-lbs). Repeat for the remaining turn signal.
Auxiliary Lamp Wiring
  1. See Figure 4. Insert the terminals on the ends of the wires into the cavities of a four-way socket housing (16) from the kit:
  • Blue turn signal wire to Cavity 1
  • Violet or Brown turn signal wire to Cavity 2
  • Black turn signal wire to Cavity 3
  • Gray/black auxiliary lamp wire to Cavity 4
1Sealed splice connector
2One wire
3Two wires
Figure 3. Splice Configuration (One Into Two)
  1. Black turn signal housings: After the wires have been secured in the socket housing (16), cut the black ground lead about 32 mm (1.25 in) from the socket housing.
  2. Use a sealed splice connector (17) to splice the black lead coming from the four-way socket housing (16) to both black leads coming from the black turn signal and auxiliary lamp housings. See Figure 3.
  3. ALL turn signal housings: Repeat for the remaining lamp assembly.
Lamp Bracket Installation
1. See Figure 1. Hold the auxiliary lamp bar assembly near the installed position. Plug the wiring connector from the lamp bar into the fairing harness connector [31LA] or [31RA] coming from the vehicle per the service manual. Position the lamp bar onto the studs. Tuck excess wiring inside the lamp bar.
2. Install two acorn nuts (12) onto the studs to attach the bar assembly to the motorcycle. Tighten the nuts to 13.6–20.3 N·m (10–15 ft-lbs).
3. Repeat Steps 1 and 2 for the opposite side.
Switch Installation
1. See the service manual. Remove dash panel.
2. Remove two screws and left side switch blank. Save screws.
3. Connect switch pack from the kit to the connector that was secured to the switch blank.
4. Install switch pack to the dash panel. Secure with two saved screws. Tighten to 1.4–1.9 N·m (12–17 in-lbs). Over-tightening damages the dash panel.
5. See service manual. Install dash panel.
COMPLETION
  1. See Figure 4 and the service manual to:
    1. Install new auxiliary lamps (D, purchased separately) using new nest rings (15) from the kit.
    2. Install the new trim rings (12) using the screws (13) and nuts (14) from the kit.
    2. NOTE
    To prevent possible damage to the sound system, verify that the ignition key switch is in the OFF position before installing the main fuse.
  2. See the service manual to install the main fuse.
  3. Check for correct function of all lighting components and switches before operating vehicle.
SERVICE PARTS
Figure 4. Service Parts, Custom Auxiliary Forward Lighting Kits
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Bar, auxiliary lamp, right (chrome)
Bar, auxiliary lamp, right (black)
68000022
68000103
2
Bar, auxiliary lamp, left (chrome)
Bar, auxiliary lamp, left (black)
68000021
68000102
3
Housing assembly,
auxiliary lamp (2)
  • (chrome)
  • (black)
.
.
67800254
67800388
4
Rubber isolator (2)
40901-05
5
Clamp block, auxiliary lamp (2)
69563-06
6
Lockwasher, internal tooth,
9.5 mm (⅜ in) ID (2)
.
7130W
7
Hex lock nut, with nylon insert,
3/8-16 (2)
.
7667
8
Standoff, turn signal (2)
  • (chrome)
  • (black)
.
68821-00
73333-10
9
Screw, hex socket button head,
5/16-18 (2)
.
1332
10
Lockwasher, helical spring,
7.9 mm (5/16 in) ID (2)
.
7041
11
Turn signal subassembly (2)
(without lens or bulb)
Not sold
separately
12
Bezel ring, auxiliary lamp (2)
  • (chrome)
  • (black)
.
68725-62A
67700120
13
Screw, #8-32 x 25.4 mm (1 in) long (2)
.
3514
14
Nut, #8-32 (2)
7606
15
Nest ring, auxiliary lamp (2)
68331-02
16
Socket housing, four-way (2)
72908-11
17
Sealed splice connector (red) (2)
(for Kit 67800366 only)
70585-93
18
Switch pack (includes Items 19-21)
69200172
19
  • Blank, switch button (2)
71400031
20
  • Fog switch, maintained contact
71400044
21
  • Switch base, dash panel
69200173
Items mentioned in text, but not included in kit.
A
Original equipment (OE) turn signal lens (2)
B
OE turn signal bulb (2)
C
OE acorn nut (4)
D
Auxiliary lamp bulb (2) (Separate purchase)