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VRSC BRACKET FOR BILLET HEADLAMP SHELL
J037202006-09-26
GENERAL
Kit Number
68211-05
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
VRSCA and VRSCB models require the separate purchase of Billet Headlamp Shell Kit 67704-03, which is available from a Harley-Davidson dealer. VRSCA models also require the separate purchase of Headlamp 68297-05, while VRSCB models use the original equipment lens assembly (including gasket and boot).
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.
Kit Contents
See Figure 6 and Table 1.
NOTICE
When replacement is required, use only the specified sealed beam unit or bulb, available from a Harley-Davidson dealer. An improper wattage sealed beam or bulb, can cause charging system problems. (00209a)
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)
REMOVAL
VRSCA Models
1. Remove windshield (if equipped). Refer to appropriate Instruction Sheet for procedures.
2. Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
3. See Figure 1. Disconnect headlamp connector (1) from vehicle wire harness.
4. Remove two screws (2), headlamp mounting bracket (3), and headlamp assembly (4) from upper bracket.
1Connector
2Screw (2)
3Bracket
4Headlamp assembly
5Screw (2)
Figure 1. VRSCA Headlamp Assembly
VRSCB Models
1. Remove windshield (if equipped). Refer to appropriate Instruction Sheet for procedures.
2. Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
3. See Figure 2. Disconnect headlamp connector (1) from vehicle wire harness.
4. Remove two screws (2), headlamp assembly (3), and headlamp mounting bracket (4) from upper bracket.
5. Remove nut (5), screw (6), and trim ring (7) from headlamp.
6. Remove lens assembly (8) from headlamp shell (9). Save lens assembly for Billet Headlamp Shell Kit 67704-03 installation.
1Connector
2Screw (2)
3Headlamp assembly (includes 5 through 9)
4Bracket
5Nut
6Screw
7Trim ring
8Lens assembly (includes gasket and boot)
9Headlamp shell
Figure 2. VRSCB Headlamp Assembly
INSTALLATION
2004-Earlier VRSCA and VRSCB Models
  1. Assemble Chrome Billet Headlamp Shell Kit (67704-03). Refer to Instruction Sheet-J03018.
    2. NOTE
    VRSCA models use Headlamp 68297-05, while VRSCB models use original equipment lens assembly (including gasket and boot).
    Adapter ring from kit ( Figure 6 , Item 1) will be used to install billet headlamp assembly on Instruction Sheet-J03018.
  2. See Figure 3. Cut the two connectors (1) from existing headlamp wire harness (2). Be sure to cut the wires as close to the back of the connector as possible.
  3. See Figure 6. Route new wire harness (2) through the hole in bottom of the billet headlamp shell (A).
    4. NOTE
    Only one 16 AWG wire will fit into pin terminals included in kit. Both black wires (ground) can be joined together, then connected to a single wire, if desired.
  4. Tape end of one black wire with electrical tape and secure it to wire harness.
  5. See Figure 3 and Figure 6. Install terminal pin (3) and socket housing (4) onto new wire harness ( Figure 6 , Item 2). Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual for installing socket/pin terminals.
1Connector (2)
2Wire harness
3Terminal pin (4)
4Socket housing
Figure 3. 2004-Earlier VRSCA and VRSCB Headlamp Wire Harness
2005-Later VRSCA and VRSCB Models
  1. Assemble Chrome Billet Headlamp Shell Kit (67704-03). Refer to Instruction Sheet-J03018.
    2. NOTE
    VRSCA models use Headlamp 68297-05, while VRSCB models use original equipment lens assembly (including gasket and boot).
    Adapter ring from kit ( Figure 6 , Item 1) will be used to install billet headlamp assembly on Instruction Sheet-J03018.
  2. Disconnect and discard existing wire harness.
  3. See Figure 6. Connect new wire harness (2) to billet headlamp shell (A).
  4. Route wire harness (2) through hole in bottom of billet headlamp shell (A) before installing socket housing (4) provided in kit.
    5. NOTE
    Brake hose bracket (not shown) may need to be removed to install headlamp base fastener (B).
2002-Later VRSCA and VRSCB Models
1. See Figure 6. Place headlamp base fastener (B) through bottom mounting plate (5) and spacer (6).
2. Position assembled bottom mounting plate and spacer below lower triple clamp (not shown), and thread fastener into billet headlamp base (A).
3. Install headlamp mounting plate (7) and triple clamp filler (8). Triple clamp filler must be installed with chamfered edge up.
4. Secure triple clamp filler with chrome socket head cap screws (9). Tighten screws to 4.5-7.5 Nm (40-66 in-lbs).
NOTE
Avoid damage to electrical system. Be sure headlamp harness terminals plug into proper terminals of the bike wire harness.
5. Connect headlamp harness male connector to female harness connector.
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
6. Install right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
7. Install windshield (if equipped). Refer to appropriate Instruction Sheet for procedures.
HEADLAMP ALIGNMENT
WARNING
The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b)
1. Verify correct front and rear tire pressure. See TIRES AND WHEELS in Service Manual.
2. Place motorcycle on level floor (or pavement) in an area with minimum light.
3. See Figure 4. Position motorcycle 7.6 m (25 ft) away from a screen or wall. Measure the vertical distance from center of headlamp to floor, and draw a horizontal line on screen or wall at same height above floor.
Figure 4. Headlamp Alignment
4. Load vehicle with rider, passenger (if normally present) and any cargo. Weight will compress vehicle suspension slightly.
5. Stand motorcycle upright with both tires on floor and front wheel held in straight alignment (direct forward).
6. See Figure 5. Turn ignition switch ON. Set handlebar headlamp switch to HI beam position.
Figure 5. Headlamp Switch
7. Check light beam for alignment.
a. The main, which is a broad, flat pattern of light, should be centered equally above and below the horizontal line.
b. The main beam of light should also be directed straight ahead. Properly adjusted headlamps project an equal area of light to right an left of center.
c. Adjust headlamp if necessary.
SERVICE PARTS
Figure 6. Service Parts: VRSC Bracket for Billet Headlamp Shell
Table 1. Service Parts: VRSC Bracket for Billet Headlamp Shell
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Ring, adapter
67769-93
7
Mounting plate, headlamp
68231-05
2
Wire harness, headlamp
68529-05
8
Filler, triple clamp
68243-05
3
Pin, terminal, 820-16 AWG (4)
73190-96
9
Screw, socket head cap, smooth M8 x 1.25 x 20 mm lg, chrome (2)
94020-03
4
Housing, socket 4-place
73104-96BK
A
Shell, billet headlamp
Not Part of Kit
5
Mounting plate, bottom
68232-05
B
Screw, headlamp base
Not Part of Kit
6
Spacer, billet headlamp mount
68539-05