BILLET HEADLAMP SHELL
J030182007-07-22
GENERAL
Kit Number
67704-03
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts 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 references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Proper installation of this kit requires the use of Snap-on® Pick Tool (TT600-3) and a silicone based lubricant, which can be purchased at a Harley-Davidson dealer.
Kit Contents
REMOVAL
Softail and Dyna Models
1.
Remove the windshield (if equipped).
2.
Remove the seat according to the procedure in the applicable Service Manual.
NOTE
Before disconnecting battery, fuel pressure must be relieved from the fuel lines of the EFI system. Refer to the applicable Service Manual for instructions.
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)
WARNING
Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)
3.
FXST/B/D models: Remove fuel tank. Refer to FUEL TANK CARBURETED or FUEL TANK: EFI in Service Manual. FXDWG models: Remove fuel tank. Refer to FUEL TANK in Service Manual.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
WARNING
Disconnect 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)
4.
Disconnect battery cables, negative (-) cable first.
5.
See Figure 1. Disconnect headlamp connector (1) from vehicle harness.
6.
Remove nut (2), screw (3), and trim ring (4) from headlamp.
NOTE
Save the following items for reuse:
  • Lens assembly (5) (includes gasket and boot)
  • Adapter ring (7)
  • Wiring harness (10) includes wiring connector block (6), headlamp connector (1), and grommet (9)
  • Lockwasher (12)
7.
Remove lens assembly (5) and disconnect wiring connector block (6) from bulb prongs.
1Headlamp connector
2Nut
3Screw
4Trim ring
5Lens assembly (includes gasket and boot)
6Wiring connector block
7Adapter ring (wave-shape cross section shown)
8Headlamp shell assembly
9Grommet
10Headlamp wire harness (includes 1, 6, and 9)
11Bolt
12Lockwasher
Figure 1. Headlamp Assembly (Softail and Dyna Models)
1Lens assembly (2004-Earlier)
2Lens assembly (2005-Later)
Figure 2. Headlamp Lens Assembly
  1. Remove adapter ring (7) from headlamp shell assembly (8).
  2. NOTE
    Record the location of the wires in the connector before removing.
  3. Remove headlamp connector (1) from headlamp wire harness using a pick tool (Snap-on® TT600-3).
  4. Work the grommet (9) through the hole in the headlamp shell (from outside of shell) using a small flat bladed screwdriver, and remove headlamp wire harness (with grommet) (10) from headlamp shell. If harness is equipped with an internal ground wire, cut ground wire off and tape end of wire with electrical tape.
  5. Remove bolt (11), lockwasher (12), and headlamp shell assembly (8).
VRSCA Models
Remove original equipment headlamp assembly. Refer to Instruction Sheet -J03720 for procedures.
NOTE
VRSCA models require the separate purchase of Headlamp 68297-05, which is available from a Harley-Davidson dealer.
VRSCB Models
Remove original equipment headlamp assembly. Refer to Instruction Sheet -J03720 for procedures.
NOTE
VRSCB models use the original equipment headlamp (and gasket).
INSTALLATION
Wiring Harness and Headlamp Mounting Block Assembly
NOTE
Use caution during installation, to prevent scratching the headlamp shell, mount and mounting block.
1.
See Figure 3. Feed headlamp wire harness (with grommet) (1) through hole in billet headlamp shell (2), but do not seat grommet (3) in hole.
2.
Softail and Dyna: Install harness wires into connector (4) in same locations as noted in removal. VRSC: Refer to Instruction Sheet -J03720 for harness wire connection.
1Headlamp wire harness
2Billet headlamp shell
3Grommet
4Connector
Figure 3. Install Wiring Harness in Billet Headlamp Shell
3.
See Figure 4. Install billet headlamp mount (1) to headlamp shell (2) using two 1/4-20 x 7/8 in. screws (3), lockwashers (4), and locknuts (5) supplied in kit. Align mount and tighten hardware until snug.
NOTE
The wiring harness should be routed along the top of the mounting block.
4.
See Figure 5. Install mounting block (1) to headlamp/mount assembly (2) using two 3/8-16 x 3/4 in. screws (3), lockwashers (4), and flat washers (5) from kit. Align mounting block and tighten hardware until snug.
5.
Softail and Dyna: See Figure 6. Install headlamp shell and mounting block assembly (1) onto headlamp mounting plate/lower bracket (2) using a 3/8-16 x 1-3/4 in. screw (3) from kit and lockwasher (4) previously removed. Align shell and mounting block, and tighten screw to 31 ft-lbs (42 Nm). VRSC: Refer to Instruction Sheet -J03720 to install headlamp shell and mounting block onto lower triple clamp.
1Billet headlamp mount
2Headlamp shell
3Screw (2)
4Lockwasher (2)
5Locknut (2)
Figure 4. Install Headlamp Mount to Headlamp Shell
1Mounting block
2Headlamp/mount assembly
3Screw (2)
4Lockwasher (2)
5Flat washer (2)
Figure 5. Install Billet Headlamp Mounting Block on Headlamp/Mount Assembly
1Headlamp shell and mounting block assembly
2Headlamp mounting plate/lower bracket
3Screw
4Lockwasher
Figure 6. Install Headlamp Shell and Mounting Block
6.
See Figure 4. Tighten 1/4 in. hardware previously installed to 108 in-lbs (12 Nm).
7.
See Figure 5. Place a protective covering between top of headlamp shell and bottom of upper bracket (Softail and Dyna) or top triple clamp (VRSC) (not shown). Tilt headlamp shell back until it just misses bottom of upper bracket/top triple clamp. Tighten screw (3) to 31 ft-lbs (42 Nm).
Headlamp Assembly
1.
Softail and Dyna Models:VRSC Models:
a.
2004 and earlier: See Figure 7. Install gasket from kit over boot and existing gasket. Position gasket according to the adapter ring (wave-shape or L-shape cross section) equipped with lens assembly.
b.
2005 and later: See Figure 8. Install gasket from kit over boot and existing gasket. Position gasket according to the adapter ring (wave-shape or L-shape cross section) equipped with lens assembly.
c.
See Figure 8. Install gasket from kit over boot and existing gasket. Position gasket according to the adapter ring (L-shape cross section) in VRSC Bracket for Billet Headlamp Shell Kit 68211-05.
NOTE
The adapter ring will be installed with the outer flange facing out, and positioned as described in the following step.
1Lens and bulb
2Gaskets (with adapter ring, item 3)
3Adapter ring (wave-shape cross section)
4Headlamp boss
5Gaskets (with adapter ring, item 6)
6Adapter ring (L-shape cross section)
Figure 7. Install Gasket (2004-Earlier Lens Assembly)
1Lens and bulb
2Gaskets (with adapter ring, item 3)
3Adapter ring (wave-shape cross section)
4Headlamp boss
5Gaskets (with adapter ring, item 6)
6Adapter ring (L-shape cross section)
Figure 8. Install Gasket (2005-Later Lens Assembly)
2.
See Figure 9. Install adapter ring (1) in headlamp shell (2), with lens boss cut-out (3) at 3 o'clock position and shell boss cut-out (4) at 8 o'clock position. VRSC models use adapter ring from Billet Headlamp Shell Kit (68211-05).
3.
Install 3-prong connector (5) onto rear of lens assembly.
NOTE
When installing the lens assembly into the shell, make sure the wiring harness grommet is seated in the hole in the shell.
4.
Install lens assembly (6) into headlamp shell (2), aligning headlamp boss (7) with lens boss cut-out (3) on adapter ring. The headlamp gasket tabs should be sandwiched between the outside diameter of the lens assembly and the adapter ring.
5.
See Figure 10. Snap retaining ring (1) from kit into groove in headlamp shell (2). It may be necessary to use a needle nose pliers for leverage to install retaining ring. The retainer should push up against front of lens. Position retainer so it does not hit headlamp bosses (3) on front of lens. Gap in retaining ring (4) should be positioned at bottom dead center.
NOTE
Do not use a petroleum based lubricant on the trim ring O-ring. Petroleum based lubricants will make the O-ring swell and make the headlamp difficult to disassemble.
1Adapter ring (L-shape cross section shown)
2Headlamp shell
3Lens boss cut-out
4Shell boss cut-out
53-prong connector
6Lens assembly (includes gaskets and boot)
7Headlamp boss
Figure 9. Install Lens Assembly
1Retaining ring
2Headlamp shell
3Headlamp bosses
4Gap in retaining ring
5O-ring
6Trim ring
Figure 10. Install Trim Ring
6.
Apply a light coat of silicone based lubricant (or soap if a silicone lubricant is not available) on the O-ring (5) surface. This will aid in disassembly of headlamp when servicing at a later date.
7.
Install O-ring (5) over groove in trim ring (6).
8.
Connect headlamp connector to vehicle wire harness.
Softail and Dyna Models
WARNING
Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)
NOTE
Be sure that wiring harness does not get pinched between fuel tank and frame during tank installation.
1.
FXST/B/D models: Install fuel tank. Refer to FUEL TANK CARBURETED or FUEL TANK: EFI in Service Manual. FXDWG models: Install fuel tank. Refer to FUEL TANK in Service Manual.
WARNING
Connect 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)
2.
Connect battery cables, positive (+) cable first.
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)
3.
Install seat according to the instructions in the Service Manual.
4.
Align headlamp as described in the alignment procedure in the applicable Service Manual. Tighten headlamp mounting hardware to 31 ft-lbs (42 Nm).
NOTE
Do not use a petroleum based lubricant on the trim ring O-ring. Petroleum based lubricants will make the O-ring swell and make the headlamp difficult to disassemble.
5.
See Figure 10. Install trim ring (6) with O-ring (5) into headlamp shell (2). Use a silicone based lubricant (or soap if a silicone lubricant is not available) on the O-ring outer diameter to ease installation.
6.
Trim windshield (if equipped). See "Trim Windshield" in this Instruction Sheet.
7.
Install windshield (if equipped). Refer to appropriate Instruction Sheet for procedures.
VRSC Models
  1. Install right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
  2. Align headlamp as described in the alignment procedure in the applicable Service Manual. Tighten headlamp mounting hardware to 31 ft-lbs (42 Nm).
  3. NOTE
    Do not use a petroleum based lubricant on the trim ring O-ring. Petroleum based lubricants will make the O-ring swell and make the headlamp difficult to disassemble.
  4. See Figure 10. Install trim ring (6) with O-ring (5) into headlamp shell (2). Use a silicone based lubricant (or soap if a silicone lubricant is not available) on the O-ring outer diameter to ease installation.
  5. Trim windshield (if equipped). See "Trim Windshield" in this Instruction Sheet.
  6. Install windshield (if equipped). Refer to appropriate Instruction Sheet for procedures.
TRIM WINDSHIELD
Table 1. FXST/FXSTB/FXDWG Windshield
Windshield Part Number
Description
Amount to Trim (1)
Rigid Windshields
91820-85A
Sport Windshield
Fits as is (None)
58025-91B
58059-93A
Compact Windshield
Higher Position - Fits as is (None)
Trim as desired, to a maximum of 1 in. (25 mm)
Detachable Windshields (Using Docking Kit 58350-96)
58340-96
58627-99
58341-96
Compact Windshield
Fits as is (None)
57965-97A
Super Sport Windshield
5/16 in. (8 mm)
Table 2. FXSTD Windshield
Windshield Part Number
Description
Amount to Trim (1)
Detachable Windshields (Using Docking Kit 58397-00)
57090-00A
57824-00A
Compact Windshield
1-1/4 to 1-1/2 in. (32 to 38 mm)
57837-00A
Super Sport Windshield
1-1/4 to 1-1/2 in. (32 to 38 mm)
NOTE
This section applies to Softail and Dyna models. It does not apply to VRSC models.
This procedure explains how to trim a Harley-Davidson windshield in order to gain needed clearance for the new headlamp shell. Refer to the appropriate chart for your model motorcycle and windshield type to determine the amount that your windshield may need to be trimmed.
  1. See Figure 11. Cover an area extending approximately 2 in. (50 mm) from windshield headlamp opening with two layers of masking tape on both sides of windshield. This tape provides a surface on which to mark the cut, as well as to protect the windshield while cutting.
  2. Mark amount to be trimmed (1) on the tape. Maintain existing radius (2) when marking new opening.
  3. Using a saber saw with a fine-toothed blade, carefully cut new opening on windshield.
  4. Clean edges of new opening with a fine-grit grinding wheel.
  5. Remove tape.
1Amount to be trimmed
2Radius
3Area to be removed
Figure 11. Windshield Trimming Dimensions
LENS AND BULB REPLACEMENT
Disassembly
WARNING
Disconnect 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)
1.
Softail and Dyna Models: VRSC Models:
a.
Remove seat according to the instructions in the Service Manual.
b.
Disconnect battery cables, negative (-) cable first.
c.
Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
2.
See Figure 12. Cover tip of small slotted screwdriver with duct tape, and insert tip of screwdriver into opening (1) at bottom of headlamp shell. Twist screwdriver to move bottom of trim ring (2) out approximately 0.12 in. (3 mm).
NOTE
If a cotter pin extractor (pick with a 90° bend) is available, it can be used as a small pry bar in place of a screwdriver.
Small flat washers or pennies can be used as shims, as each washer/penny is approximately 0.060 in. (1.5 mm) thick.
The trim ring can be removed without damaging either the trim ring or headlamp shell. Taping the shims in place allows one person to remove the trim ring without damaging the chrome.
1Opening
2Trim ring
Figure 12. Pry Bottom of Trim Ring Away from Headlamp Shell
3.
See Figure 13. Insert shim(s) (1) equal to approximately 0.12 in. (3 mm) in gap between trim ring (2) and headlamp shell (3). Tape shim(s) to trim ring and headlamp shell to hold them in place.
4.
Insert a 0.06 in. (1.5 mm) shim (4) into gap to the right of shims at the bottom of trim ring, and slide shim in gap counterclockwise until it sticks. The shim should now be at approximately the 2 or 3 o'clock position. Tape shim in place.
5.
Insert a 0.06 in. (1.5 mm) shim (5) into gap to the left of shims at the bottom of trim ring, and slide shim in gap clockwise until it sticks. The shim should now be at approximately the 9 or 10 o'clock position. Tape shim in place.
1Shim, 0.12 in. (3 mm)
2Trim ring
3Headlamp shell
4Right shim, 0.06 in. (1.5 mm)
5Left shim, 0.06 in. (1.5 mm)
Figure 13. Remove Trim Ring
6.
Cover tip of a small slotted screwdriver with duct tape, and insert tip of screwdriver in gap between 0.06 in. (1.5 mm) shims (4 and 5) and bottom of headlamp shell. Starting near shims, and alternating from side to side, carefully pry trim ring from headlamp shell.
7.
See Figure 14. Using a needle nose pliers, remove retaining ring (1) from groove in headlamp shell (2).
8.
Carefully pull lens assembly (3) out of headlamp shell, and disconnect wiring connector block (4) from bulb prongs.
9.
Remove boot (5) and gasket (6), and gasket (7) from lens assembly.
NOTICE
Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Handle the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210b)
WARNING
Handle bulb carefully and wear eye protection. Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062b)
10.
Replace headlamp bulb according to the procedure in the applicable Service Manual.
1Retaining ring
2Headlamp shell
3Lens assembly
4Wiring connector block
5Boot
6Gasket
7Gasket
Figure 14. Remove Lens Assembly
Headlamp Assembly
  1. Softail and Dyna Models:VRSC Models:
    1. 2004 and earlier: See Figure 7. Install gasket from kit over boot and existing gasket. Position gasket according to the adapter ring (wave-shape or L-shape cross section) equipped with lens assembly.
    2. 2005 and later: See Figure 8. Install gasket from kit over boot and existing gasket. Position gasket according to the adapter ring (wave-shape or L-shape cross section) equipped with lens assembly.
    1. See Figure 8. Install gasket from kit over boot and existing gasket. Position gasket according to the adapter ring (L-shape cross section) in VRSC Bracket for Billet Headlamp Shell Kit 68211-05.
  2. NOTE
    The adapter ring will be installed with the outer flange facing out, and positioned as described in the following step.
  3. See Figure 9. Install adapter ring (1) in headlamp shell (2), with lens boss cut-out (3) at 3 o'clock position and shell boss cut-out (4) at 8 o'clock position. VRSC models use adapter ring from Billet Headlamp Shell Kit (68211-05).
  4. Install 3-prong connector (5) onto rear of lens assembly.
  5. NOTE
    When installing the lens assembly into the shell, make sure the wiring harness grommet is seated in the hole in the shell.
  6. Install lens assembly (6) into headlamp shell (2), aligning headlamp boss (7) with lens boss cut-out (3) on adapter ring. The headlamp gasket tabs should be sandwiched between the outside diameter of the lens assembly and the adapter ring.
  7. See Figure 10. Snap retaining ring (1) from kit into groove in headlamp shell (2). It may be necessary to use a needle nose pliers for leverage to install retaining ring. The retainer should push up against front of lens. Position retainer so it does not hit headlamp bosses (3) on front of lens. Gap (4) in retaining ring should be positioned at bottom dead center.
  8. NOTE
    Do not use a petroleum based lubricant on the trim ring O-ring. Petroleum based lubricants will make the O-ring swell and make the headlamp difficult to disassemble.
  9. Apply a light coat of silicone based lubricant (or soap if a silicone lubricant is not available) on the O-ring (5) surface. This will aid in disassembly of headlamp when servicing at a later date.
  10. Install O-ring (5) over groove in trim ring (6).
Softail and Dyna Models:
WARNING
Connect 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 battery cables, positive (+) cable first.
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 seat according to the instructions in the Service Manual.
3.
Align headlamp as described in the alignment procedure in the applicable Service Manual. Tighten headlamp mounting hardware to 31 ft-lbs (42 Nm).
NOTE
Do not use a petroleum based lubricant on the trim ring O-ring. Petroleum based lubricants will make the O-ring swell and make the headlamp difficult to disassemble.
4.
See Figure 10. Install trim ring (6) with O-ring (5) into headlamp shell (2). Use a silicone based lubricant (or soap if a silicone lubricant is not available) on the O-ring outer diameter to ease installation.
VRSC Models:
  1. Install right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
  2. Align headlamp as described in the alignment procedure in the applicable Service Manual. Tighten headlamp mounting hardware to 31 ft-lbs (42 Nm).
  3. NOTE
    Do not use a petroleum based lubricant on the trim ring O-ring. Petroleum based lubricants will make the O-ring swell and make the headlamp difficult to disassemble.
  4. See Figure 10. Install trim ring (6) with O-ring (5) into headlamp shell (2). Use a silicone based lubricant (or soap if a silicone lubricant is not available) on the O-ring outer diameter to ease installation.
SERVICE PARTS
Figure 15. Service Parts: Billet Headlamp Shell
Table 3. Service Parts: Billet Headlamp Shell
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Screw, hex socket button 1/4-20 x 7/8 in. (2)
94387-92T
9
O-ring
11385
2
Lockwasher (2)
94080-90T
10
Retaining ring
67706-03
3
Locknut, 1/4-20 (2)
7686
11
Trim ring
67709-03
4
Screw, hex socket button 3/8-16 x 3/4 in. (2)
94399-92T
12
Shell, billet headlamp
Not Sold Separately
5
Lockwasher, 3/8 in. (2)
94082-90T
Mount kit
67754-03
6
Washer, flat, chrome 3/8 in. (2)
94067-90T
13
  • Mount
Not Sold Separately
7
Screw, hex socket head 3/8-16 x 1-3/4 in. (not shown)
94357-91T
14
  • Mounting block
Not Sold Separately
8
Gasket
67601-94A