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LED PROJECTOR, HEADLAMP KIT
J064932019-06-11
GENERAL
Kit Number
67700430, 67700433
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)
WARNING
Be sure to use the specified wiring harness. Failure to use the specified wiring harness can cause unintended loss of power to the front or rear lights, reducing rider visibility, which could result in death or serious injury. (06709a)
Separate purchase and installation of additional parts or accessories could be required for proper installation of this kit.
  • All FLD and FLRT, 2017 and earlier Softail, 2009-2013 Touring and Tri Glide Models require wire harness 69201070, Models listed above (except FLD, FLRT, and 2011-2017 Softail) with position lamp spade connections accessible at the headlamp may optionally use 69201470 instead
  • 2009-2013 Touring and Tri Glide, All Freight Train Nacelle equipped Softails, and All FLD Models require headlamp mounting ring kit 67700439
NOTE
Harness 69201070 has no connector for position lamp circuit, while 69201470 does. Use of harness 69201470 will allow the position lamp ON in accessory mode. Use of harness 69201070 will force the position lamp OFF in accessory mode. Position lamp function is identical in all other modes for either of these harnesses. See Figure 8 item 3.
NOTE
See Figure 4. Harness 69201775 provides an optional connection to vehicle accessory connector (2) that forces position lamp ON in accessory mode. Not connecting 69201775 to vehicle accessory will force position lamp OFF in accessory mode. The 4-way connectors (4 and 5) on 69201775 must be used where 69201775 is required. Headlamp functions in conjunction with low and high beams regardless of connection to vehicle accessory.
NOTE
Softail and FLRT do not use the black retaining ring included in this kit. Use stock stainless or black retaining ring 67700487 available for separate purchase.
NOTE
This instruction sheet refers to service and electrical diagnostic manual information. These manuals for this year/model motorcycle are required for this installation. They are available from a Harley-Davidson dealer.
NOTE
2014-Later Touring: See Figure 4. If other accessories are connected to the vehicle accessory connector (2), adapter 69200921 may be required to perform optional installation steps.
NOTE
Where stated in this instruction sheet, some vehicles require a harness that intentionally disconnects position lamp pin on headlamp. This prevents vehicle's position circuit from supplying headlamp power. Do not bypass this harness even if headlamp initially operates correctly without it. See warning 06709a.
Standard Current Draw
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)
WARNING
For BCM (Body Control Module) equipped motorcycles, be sure to use the specified BCM headlamp setting. Failure to set the BCM correctly can cause unintended loss of power to the headlamp, reducing rider visibility, which could result in death or serious injury. (06708a)
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)
The headlamp installed with this kit requires a total of up to 5 amps of current from the electrical system.
Kit Contents
See Figure 15 and Table 3.
REMOVAL
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
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)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Remove headlamp. See service manual.
  2. See Figure 1. For all installations with mounting rings, set initial clearance behind headlamp by rotating the three adjustment screws (1) until about 3/8 inch of the springs (3) are exposed above assembly's screw flange (4). Ensure full weld nut (2) thread engagement with adjustment screws (1) before and after headlamp installation and aiming.
  3. See Figure 3. If equipped, remove headlamp's dual halogen jumper.
    4. NOTE
    Accessory trim ring may limit range of mounting ring adjustment screws. Adjustment screws can be tightened further during aiming procedure to ensure trim ring has clearance to the headlamp.
  4. See service manual. Reconnect battery cables and main fuse to perform this step. If equipped with Body Control Module (BCM), verify and set BCM headlamp configuration. All BCM equipped vehicles require this step regardless if headlamp initially operates in vehicle's current configuration. See BCM Setting Instructions. Remove battery cables and main fuse before continuing.
  5. Optional: 2014 and later Touring and Tri Glide: For vehicles with fairings, remove outer fairing and windshield if position lamp is desired ON in accessory mode.
    6. NOTE
    If a high or low beam open code was set, clear this following installation of headlamp. See electrical diagnostic manual.
1Adjustment screw
2Weld nut
3Spring
4Screw flange
Figure 1. Installations with Mounting Ring
INSTALLATION
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)
NOTE
If headlamp remains loose following proper installation, see Headlamp Spacer Installation.
NOTE
Headlamp rear cover is pre-installed to headlamp housing and is required for all non-bucket installations. Screws have been torqued to the correcting setting of 7.6-9.2 Nm (68-82 in-lbs). Due to the depth of the lamp, contact of cables behind the lamp on the rear cover may occur.
    2014 and Later Touring (except Road King) and Tri Glide Models:
  1. See Figure 4. If outer fairing was removed, perform step 1a and 1b. Otherwise, skip to step 2. Locate vehicle accessory connector (2).
    1. Connect 2-way accessory connector (1) of 69201775 to vehicle accessory connector (2).
    2. Secure leg of harness by routing down the right side of fairing following vehicle wire harness. Secure harnessing using cable straps from kit.
  2. If optional removal step was not performed, cut off, electrical tape and secure accessory connector (1) wire of harness 69201775. Ensure dynamic movement of harnessing and other parts behind the lamp will not be restricted by moving handlebars from fork lock left to fork lock right.
  3. Connect headlamp connectors (4 and 5) on harness 69201775 between fairing headlamp connector (3) and headlamp connection (6).
  4. Install headlamp and retaining ring. See service manual.
  5. Install headlamp door (trim ring). See service manual.
  6. Install battery cables and main fuse. See service manual.
  7. Remove warning labels from headlamp lens.
    8. NOTE
    Due to headlamp's optic design, viewing from above it may not look like headlamp's top center optic is ON in low beam. This can be verified by viewing the optic at an upward angle using eye protection. See Figure 2 for optic illumination diagram.
  8. Aim headlamp per Headlamp Alignment Procedure.
    1Position (Accessory mode only, some models require optional steps)
    2Low beam
    3High beam
    Figure 2. Modes of Operation
    Figure 3. Removal of Dual Halogen Harness Adapter
    1Accessory Connector [299]
    2Accessory Connector [299]
    3Fairing Headlamp Connector [38]
    4Headlamp Connector [38]
    5Headlamp Connector [38]
    6Headlamp Connection
    AAdapter 692011775 (consists of items 1,4,5)
    Figure 4. Accessory Connectors - Touring
    2014-Later Road King models:
  1. See Figure 5. Locate connector [38HI] and [38LO] (1 and 3).
  2. Optional step: If position lamp is desired ON in accessory mode follow steps 2 a-b, otherwise skip to step 3. Refer to Figure 5 and Figure 6. See Sealed Splice Connector Repair section.
    1. 2014-2016: Cut off accessory connector (6) on 69201775 (5). Splice to violet/blue wire connected to vehicle connector [67] (toggle switch). See Figure 15 , item 4.
    2. 2017 and Later: Cut off accessory connector (6) on 69201775 (5). Splice to violet/blue wire connected to vehicle connector [205] (toggle switch). See Figure 15 , item 4.
  3. If optional step was not performed, cut off, electrical tape and secure accessory connector (6) wire of harness 69201775.
    1. Cut off "PIN" side of 4-way connector on adapter 69201775 from kit. Maintain as much length as possible.
    2. Cut and remove both [38HI] and [38LO] (1 and 3) connectors from vehicle harness. Maintain as much length as possible.
      Figure 5. Wiring harness Modification - Road King
  5. See Figure 6. Splice remaining wires (use red splices in kit for connecting 16 AWG wire to 18 AWG wire). Electrical tape and secure extra black ground wire. See Sealed Splice Connector Repair procedure. See Figure 15 , item 4.
  6. Route wire harnessing and secure with cable straps. Ensure dynamic movement of harnessing and other parts behind lamp will not be restricted by moving handlebars from fork lock left to fork lock right.
  7. Connect 4-way socket side of adapter 69201775 to headlamp.
  8. Install headlamp and retaining ring. See service manual.
  9. Install headlamp door (trim ring). See service manual.
  10. Install battery cables and main fuse. See service manual.
  11. Remove warning labels from headlamp lens.
    12. NOTE
    Due to headlamp's optic design, viewing from above it may not look like headlamp's top center optic is ON in low beam. This can be verified by viewing the optic at an upward angle using eye protection. See Figure 2 for optic illumination diagram.
  12. Aim headlamp per Headlamp Alignment Procedure.
    ACap with electrical tape
    Figure 6. Wiring harness Modification - Road King
Table 1. Wire Color Codes
ALPHA CODE
WIRE COLOR
BE
Blue
BK
Black
BN
Brown
GN
Green
GY
Gray
LBE
Light Blue
LGN
Light Green
O
Orange
PK
Pink
R
Red
TN
Tan
V
Violet
W
White
Y
Yellow
    2013-Earlier Touring, All FLD, All FLRT, and 2017-Earlier Softail Models:
  1. Complete installation of mounting ring. See service manual.
  2. For bucket (FLD, FLRT, and Softail without freight train nacelle) installations only: See Figure 7. Remove and discard cover (2) and four screws (3) from back of headlamp.
  3. Connect required harness (4) between vehicle harness connector (1) and headlamp.
    4. NOTE
    Position lamp will not illuminate in accessory mode if unconnected. Where harness 69201470 is allowed, connect spade to vehicle side positive spade.
  4. Electrical tape and secure any additional connectors within bucket.
  5. Ensure dynamic movement of harnessing and other parts behind lamp will not be restricted by moving handlebars from fork lock left to fork lock right. Secure harnessing using cable straps from kit.
  6. Complete headlamp installation. See service manual.
  7. Install battery cables and main fuse. See service manual.
  8. Remove warning labels from headlamp lens.
    9. NOTE
    Due to headlamp's optic design, viewing from above it may not look like headlamp's top center optic is ON in low beam. This can be verified by viewing the optic at an upward angle using eye protection. See Figure 2 for optic illumination diagram.
  9. Aim headlamp per Headlamp Alignment Procedure.
    Figure 7. Wiring Harness Installation - Softail, FLRT and FLD
Headlamp Alignment Procedure
1Light Emitting Diode (LED) Headlamp
2Centerline of low beam
3Signature Ring (Position Lamp for International Models)
Figure 8. LED Headlamp Configuration
NOTE
The alignment procedure for an LED headlamp is performed on both the low beam and the high beam. Read these instructions thoroughly to align the LED headlamp.
  1. Install main fuse. See service manual.
  2. Check tire pressure. See owner's manual.
  3. Fill fuel tank or add an equal amount of ballast.
  4. Position motorcycle so front axle is 7.6 m (25 ft) (3) from wall.
    5. NOTE
    The weight of the rider compresses the suspension slightly. Have a person whose weight is roughly the same as the principal rider sit on the motorcycle.
  5. Refer to Figure 8 and Figure 9. With vehicle laden and upright, point the front wheel straight forward at wall. Measure the distance from the floor to the center of the low beam lens (4). Record this measurement.
  6. See Figure 9. Draw a horizontal line on the wall at (5) on the wall that is the same measurement as recorded in Step 5.
  7. Draw a vertical line (2) off the perpendicular line (1) so it crosses through the horizontal line drawn in the previous step.
  8. Verify that all other lights are OFF during the alignment procedure.
1Perpendicular line
2Vertical line
325 feet (7.6 meters)
4Low beam lens centerline
5Horizontal line - align top of left side of low beam (for vertical alignment)
Figure 9. Checking Headlamp Alignment
Alignment of High Beam (Left-to-Right Alignment)
  1. Verify that the headlamp lens is perpendicular to the front forks for proper left-to-right alignment.
  2. See Figure 10. With vehicle laden and upright, point the front wheel straight forward at wall.
  3. Turn on the high beam. Align the center of the high beam such that the beam pattern is symmetric on the left and right side of vertical line (3).
1Outline of high beam light pattern
2Horizontal line
3Intersection of horizontal and vertical lines
Figure 10. Alignment of Headlamp High Beam
Alignment of Low Beam (Vertical Alignment)
1. See Figure 11. Align the horizontal cutline of low beam light pattern (3) with horizontal line (2) drawn on the wall.
1Outline of low beam light pattern
2Horizontal line
3Cutline low beam light pattern
4Vertical line
Figure 11. Alignment of Headlamp Low Beam
HEADLAMP SPACER INSTALLATION
Spacers are only intended for headlamps that remain loose following installation of proper retaining ring. Spacers are not designed to make retaining rings interchangeable.
1. Clean mounting ring surface with standard 50/50 rubbing alcohol/water in the spacer application area.
2. Remove spacers from kit.
3. Remove backer from one of the spacers and install on mounting ring by aligning with clocking feature.
4. Repeat step 3 for the two remaining spacers.
1Spacers (3)
Figure 12. Adhesive Spacer Placement
BCM SETTING INSTRUCTIONS
NOTE
You may see no change in the operation of your headlamp when BCM setting changes. However, the correct BCM headlamp setting changes the current limit to prevent overcurrent when combined with other Original Equipment Manufacturer (OEM) and accessory parts. Several factors can increase the current draw of the headlamp up to stated maximum. The correct setting is required on all models.
NOTE
Standard headlamp setting disables the low beam circuit when high beam switch is ON. Dual Halogen headlamp setting enables both the low and high beam circuits when the high beam switch is ON. If the vehicle currently uses Dual Halogen setting, any devices powered from the low beam circuit will no longer be powered when high beam is on and BCM is set to Standard.
1. This kit requires BCM set to standard headlamp mode. Your vehicle may already have the correct setting from the factory. Verify this using the "Verification of Headlamp Setting Procedure" section.
NOTE
Only Digital Technician can change the headlamp setting from Standard back to Dual Halogen.
a. If the setting is not correct, your dealer can set the BCM directly using Digital Technician or BCM can be programmed using the "Headlamp Configuration Procedure" section below.
b. Verify the setting took effect. See "Verification of Headlamp Setting Procedure" section.
Verification of Headlamp Setting Procedure
NOTE
See service manual to determine headlamp connector high and low beam wire.
1. With headlamp disconnected, verify vehicle's headlamp plug does not have a jumper attached from a previous installation.
2. Obtain a volt meter and set to Volts of Direct Current (VDC).
3. Ensure meter leads are inserted into correct position on meter. See meter's user manual.
4. Turn vehicle to ignition (engine off) mode.
5. Measure battery voltage. A convenient location to do so is battery tender plug. Record this value.
6. Verify low beam switch is ON.
7. Insert positive probe into low beam socket on headlamp connector.
8. Insert negative probe into ground socket on headlamp connector.
9. Verify meter is reading within 2VDC of previously recorded battery voltage.
10. Turn high beam switch ON.
11. Measure low beam at headlamp connector again per step 7 and 8. If the meter reads less than 3VDC (reading close to zero voltage), vehicle BCM is set to Normal mode.
a. If meter reading does not change when high beam switch is turned ON, BCM is set to Dual Halogen mode. Repeat Headlamp Configuration Procedure to set BCM to Standard mode and reverify the setting took effect.
Headlamp Configuration Procedure
1. Follow procedure to set BCM to Standard mode:
a. Turn vehicle to ignition mode.
b. Verify engine is OFF.
c. Press and hold left turn button.
d. While pressing left turn button, press flash to pass button at least 5 times within 10 seconds.
e. Headlamp should now be set to Standard mode.
f. Alternatively, Digital Technician can be used to set BCM directly. See dealer.
g. Continue to "Verification of Headlamp Setting Procedure".
SEALED SPLICE CONNECTOR REPAIR
General
Splice connectors and several Original Equipment (OE) ring terminal connectors use heat shrink covering to seal the connection.
Preparing Wire Leads
NOTE
When splicing adjacent wires, stagger the splices that the sealed splice connectors will not touch each other.
  1. Using a shop gauge, identify the gauge of the wire.
  2. Match the wire gauge to a sealed splice connector by color and part number. Refer to Table 3.
  3. Strip insulation off the wire lead. Refer to Table 3.
Table 2. Sealed Splice Connectors
WIRE GAUGE
COLOR
PART NO.
STRIP LENGTH
in
mm
18-20 (0.5-0.8 mm)
Red
70585-93
3/8
9.5
14-16 (1.0-2.0 mm)
Blue
70586-93
3/8
9.5
10-12 (3.0-5.0 mm)
Yellow
70587-93
3/8
9.5
NOTE
If any copper wire strands are cut off of the wire core, trim the end and strip the wire again in a larger gauge stripper.
Splicing Wire Leads
NOTE
See Figure 14. The connector is crimped on one side and then the other.
  1. See Figure 13. Open the PACKARD CRIMPING TOOL (Part Number:HD-38125-8) ratchet by squeezing the handles closed.
  2. Match the connector color to the wire gauge crimp die in the jaws. Insert one end of the sealed connector.
  3. Gently squeeze the handles until the connector is held in the jaws.
  4. See Figure 14. Feed the stripped end of a wire into the connector until the wire stops inside the metal insert (1).
  5. Squeeze the handles tightly closed to crimp the lead in the insert (2). The tool automatically opens when the crimping is complete.
  6. Slide the connector to the other half of the metal insert. Insert the stripped wire lead (1) until it stops. Crimp the lead in the insert (2).
WARNING
Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a)
  • Avoid directing heat toward any electrical system component that is not being serviced.
  • Always keep hands away from tool tip area and heat shrink attachment.
  1. Use an ULTRA TORCH UT-100 (Part Number:HD-39969), or a ROBINAIR HEAT GUN (Part Number:HD-25070) with a HEAT SHIELD ATTACHMENT (Part Number:HD-41183), to heat the connector from the center of the crimp (3) out to each end.
NOTE
It is acceptable for the splice to rest against the heat shrink tool attachment.
Inspecting Seals
See Figure 14. Allow the splice to cool and inspect the seal. The insulation should appear smooth and cylindrical. Melted sealant will have extruded out the ends (4) of the insulation.
1Red connector die
2Blue connector die
3Yellow connector die
Figure 13. Packard Crimping Tool (HD-38125-8)
1Wire lead in metal insert
2Crimp metal insert
3Center of crimp
4Melted SEALANT
Figure 14. Sealed Splice Connector
SERVICE PARTS
Figure 15. Service Parts: LED Headlamp Kit
Table 3. Service Parts: LED Headlamp Kit
Item
Description (Quantity)
Part Number
1
Headlamp, 7 in. LED (black)
Not sold separately
Headlamp, 7 in. LED (chrome)
Not sold separately
2
Cover, rear
67700459
3
Screw, Torx button head with lockpatch
10200032
4
Connector (red) (4)
70585-93
5
Adhesive spacer (3)
12400176
6
Cable straps
10006
7
Wire harness adapter
69201775
8
Retaining ring
for Kit 67700430
67700068