CUSTOM AUXILIARY FORWARD LIGHTING KITS

J057652025-01-22

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
67800366, 67800367	Safety Glasses, Torque Wrench

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: Custom Auxiliary Forward Lighting Kits

Table 2. Kit Contents: Custom Auxiliary Forward Lighting Kits

	Verify that all contents are present in the kit before installing or removing items from vehicle.
	Item	Qty	Description	Part No.	Notes
	1	1	Bar, auxiliary lamp, right, chrome	68000022
	1	1	Bar, auxiliary lamp, right, black	68000103
	2	1	Bar, auxiliary lamp, left, chrome	68000021
	2	1	Bar, auxiliary lamp, left, black	68000102
	3	2	Housing assembly, auxiliary lamp, chrome	67800254
	3	2	Housing assembly, auxiliary lamp, black	67800388
	4	2	Rubber isolator	40901-05
	5	2	Clamp block, auxiliary lamp	69563-06
	6	2	Lockwasher, internal tooth, 9.5 mm (3/8 in) ID	7130W
	7	2	Hex lock nut, with nylon insert, 3/8-16	7667
	8	2	Standoff, turn signal, chrome	68821-00
	8	2	Standoff, turn signal, black	73333-10
	9	2	Screw, hex socket button head, 5/16-18	1332
	10	2	Lockwasher, helical spring, 7.9 mm (5/16 in) ID	7041
	11	2	Turn signal sub-assembly, without lens or bulb	Not sold separately
	12	2	Bezel ring, auxiliary lamp, chrome	68725-62A
	12	2	Bezel ring, auxiliary lamp, black	67700120
	13	2	Screw, #8-32 x 25.4 mm (1 in) long	3514
	14	2	Nut, #8-32	7606
	15	2	Nest ring, auxiliary lamp	68331-02
	16	2	Socket housing, four-way	72908-11
	17	2	Sealed splice connector, red	70585-93	Kit: 67800366 only
	18	1	Switch pack (includes items 19-21)	69200172
	19	2	Blank, switch button	71400031
	20	1	Fog switch, maintained contact	71400044
	21	1	Switch base, dash panel	69200173
Items mentioned in text, but not included in kit
	A	2	Original Equipment (OE) turn signal lens
	B	2	OE turn signal bulb
	C	4	OE acorn nut
	D	2	Auxiliary lamp bulb (separate purchase)

GENERAL

Instruction sheet is also available electronically. To verify you are using the most current version available, do one of the following:

Go to h-d.com/isheets
Scan QR code in upper left corner of the instruction sheet

NOTE

This instruction sheet may have a Supplemental Video to assist installer in clarifying a certain part of the assembly. A linked video would be located at the end of this instruction sheet.

Models

For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

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 references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.

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.

PREPARE

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

NOTE

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.
Vehicles without security siren: See service manual to remove main fuse.

1.	Remove OE left and right turn signal bars. See service manual. NOTE Mark all wires before removal to aid in proper installation. a. See Figure 1. Remove and retain turn signal lenses (A), bulbs (B) and acorn nuts (C) for later assembly. b. Discard remaining turn signal components.
2.	Disconnect left and right turn signal connectors. See service manual.
3.	Position turn signal connectors and auxiliary lamp connectors for auxiliary lamp kit installation. See service manual.

Auxiliary Lamp Assembly

NOTE

Auxiliary Lamp Kit requires partial assembly before installation to the Vehicle.

1.	See Figure 2. Get a lamp bar (1), lamp housing (3), rubber isolator (4), clamp block (5), lockwasher (6) and locknut (7) from kit. a. Install lamp housing into lamp bar. b. Fasten with lockwasher and locknut. Tighten. Torque: 19–24 N·m (14–18 ft-lbs) c. Assemble remaining lamp bar in the same way.
2.	See Figure 3. Chrome auxiliary lamp housing: Insert terminated end of gray/black wire through hole in mounting stud on lamp housing (1).
3.	See Figure 3. Black auxiliary lamp housing: Insert terminated end of gray/black wire and bare ends of black wires through hole in mounting stud on lamp housing (1).
4.	See Figure 3. ALL housing: Route wiring through both larger internal passages in lamp bracket until knot inside auxiliary lamp housing bottoms in housing (1).
5.	See Figure 1. Get a turn signal sub-assembly (11), turn signal stand off (8), hex socket head screw (9) and lockwasher (10) from kit. a. Install bulb and lens removed from OE turn signal into turn signal sub-assembly.
6.	Install new turn signal assembly to standoff by routing wires through the standoff, into internal passages in lamp bracket alongside the gray/black wire.
7.	Slide turn signal and auxiliary lamp wiring through internal passages of auxiliary lamp bar. a. Secure turn signal assembly with lockwasher and hex socket head screw. Tighten. Torque: 10.8–13.6 N·m (96–120 in-lbs) b. Repeat for remaining turn signal.

1	Lamp bar
2	Nest ring
3	Auxiliary lamp housing
4	Rubber isolator
5	Clamp block
6	Lockwasher, internal tooth
7	Lock nut with nylon insert
8	Turn signal standoff
9	TORX head screw (2)
10	Washer (2)
11	Turn signal assembly (2)
12	Acorn nut (4)

Figure 2. Auxiliary Lamp Assembly (Wiring not shown)

1	Auxiliary lamp housing
2	Socket housing

Figure 3. Lamp Wiring Routing Shown

Auxiliary Lamp Wiring

See Figure 1. Insert terminals on ends of wires into cavities of a four-way socket housing (16) from 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

2.	Black turn signal housings: After wires have been secured in the socket housing (16), cut the black ground lead about 32 mm (1.25 in) from socket housing.
3.	See Figure 4. Use a sealed splice connector (17) to splice black lead coming from four-way socket housing (16) to both black leads coming from black turn signal and auxiliary lamp housings.
4.	ALL turn signal housings: Repeat for the remaining lamp assembly.

1	Sealed splice connector
2	One wire
3	Two wires

Figure 4. Splice Configuration (One Into Two)

Lamp Bracket Install

1.	See Figure 2. Hold the auxiliary lamp bar assembly near the installed position. a. Plug wiring connector from lamp bar into fairing harness connector [31LA] or [31RA] coming from vehicle. See service manual. b. Position lamp bar onto the studs. c. Tuck excess wiring inside lamp bar.
2.	Install two acorn nuts (12) onto studs to attach bar assembly to vehicle. Tighten. Torque: 13.6–20.3 N·m (10–15 ft-lbs)
3.	Repeat steps for opposite side.

Switch Install

1.	Remove dash panel. See service manual.
2.	Remove two screws and left side switch blank. Retain screws for later use.
3.	Connect switch pack from kit to connector that was secured to switch bank.
4.	Install switch pack to dash panel using OE screws. Tighten. Torque: 1.4–1.9 N·m (12–17 in-lbs) NOTE Over-tightening damages the dash panel.
5.	Install dash panel. See service manual.

COMPLETE

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.

1.	See Figure 1 and service manual to: a. Install new auxiliary lamps (D, purchased separately) using new nest rings (15) from kit. b. Install new trim rings (12) using screws (13) and nuts (14) from kit.
2.	Install main fuse. See service manual.
3.	Check for correct function of all lighting components and switches before operating vehicle.