Headlamp Visor Kit
J013402013-11-01
GENERAL
Kit Numbers
68129-97, 69730-01
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 4 and Table 1.
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.
INSTALLATION
1. See Figure 1. Remove the headlamp bracket plug (2) off the top of the headlight with a small flat screwdriver.
2. Remove the nut (1) underneath the plug as shown. Replace the nut with the hex spacer from kit. Leave the nut loose until Step 5 is complete.
3. See Figure 4. Install the edge gasket to the headlamp visor. The gasket should be installed at the headlamp opening as indicated in illustration. When installing gasket, start at the top of the headlamp opening and work gasket into place, finishing with the seam at the top.
4. For 2005 and later Dyna models, remove the instrument assembly to access the headlamp visor mounting bolts. Place a protective cloth on the fuel tank to prevent scratches. Remove the instrument bracket bolts and set the instrument assembly out of the way.
5. See the service manual. Align and secure headlamp.
6. Attach the rubber mount (9) to the hex spacer (10) and tighten securely.
7. Remove the bolts attaching the headlamp bracket to the vehicle. Attach the visor mount bracket (2) to the top of the headlamp bracket as follows: Dyna models: bolts (5), washers (6) and spacer (7) as shown. Sportster models: bolts (5), washers (6) and spacer (8) as shown. Attach visor mounting bracket with screw (4) and washer (3) to rubber isolator mount. Leave bracket loose until Step 8.
8. Attach visor to visor mount bracket with three screws (4) and washers (3) as shown. Align the complete headlamp visor assembly flush to the rim of the headlight and tighten all screws to 40 in-lbs (4.5 Nm). Tighten the bolts (5) to 12-15 ft-lbs (16.3-20.3).
1Hex nut
2Headlamp bracket plug
3Bolts
4Headlamp bracket
Figure 1. Headlamp Assembly
Figure 2. New Clutch Cable Routing
Figure 3. Clutch Cable Adjustment
9. For 2005 and later Dyna models, Install the instrument assembly previously removed in Step 4. Adjust the handlebars and tighten the screws to 70-80 in-lbs (7.9-9.0 Nm).
NOTE
If the clutch cable is rubbing on the headlamp visor, proceed to Step 10.
10. See Figure 2. Relocate clutch cable to the inside of the handlebars:
a. Slide rubber boot off cable adjuster. Adjuster is located approximately halfway along clutch cable by the front frame downtube.
b. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using a 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce a large amount of freeplay at the hand lever.
c. Remove small snap ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin and clutch hand lever from bracket.
d. See Figure 2. Reroute clutch cable to the inside of the handlebars and reconnect clutch cable to clutch lever by reversing step c.
e. See Figure 3. Turn cable adjuster away from jam nut until slack is eliminated at hand lever. Pull clutch cable ferrule away from clutch lever bracket to check free play. Turn cable adjuster as necessary to obtain 1/16 to 1/8 inch (1.6-3.2 mm) free play between end of cable ferrule and clutch lever bracket.
f. Hold adjuster with 1/2 inch wrench. Using 9/16 inch wrench, tighten jam nut against cable adjuster. Cover cable adjuster mechanism with rubber boot.
Figure 4. Service Parts
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Headlamp visor
Not sold separately
2
Visor mount bracket
Not sold separately
3
Washer (4)
6424
4
Screw (4)
4363
5
Bolt (2)
4816A
6
Washer, 5/16 (2)
6702
7
Spacer, .46 in. thick (2) (Dyna only)
5751
8
Spacer, .125 in. thick (2) (Sportster only)
6109
9
Rubber isolator mount
Not sold separately
10
Hex spacer
Not sold separately
11
Stock components
12
Rubber gasket (not shown)
68134-97
NOTE: Place gasket around interior edge of headlamp visor opening.