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DUAL-BULB HALOGEN HEADLAMP KIT
J051772011-02-22
GENERAL
Kit Number
67700032
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Tools and Supplies Required
Electrical Contact Lubricant (Part No. 99861-02) or equivalent is required after battery cable disconnection. This item is available from a Harley-Davidson dealer.
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 6 and Table 1.
PREPARATION
NOTE
For 2007 and later vehicles equipped with security siren:
  • Verify that the Hands-Free Fob is present.
  • Turn the ignition key switch to IGNITION.
For Vehicles With Main Fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the service manual and follow the instructions to remove the main fuse.
For Vehicles With Main Circuit Breaker:
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)
  1. Refer to the service manual and follow the instructions to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware.
REMOVAL
ALL models: See Figure 1. Remove the Phillips screw (1) at the bottom of the chrome ring. Remove chrome ring. Save parts for kit installation.
1Phillips screw
2Chrome ring
Figure 1. Remove Chrome Ring - FLHT Shown
FLHT Models
NOTE
Remove the entire mounting ring assembly (with headlamp) from the fairing.
1. See Figure 2. Remove and save TORX® screws (1) that secure mounting ring assembly (2) to fairing.
1TORX screw (4)
2Mounting ring assembly
3Screws (3)
4Retaining ring
Figure 2. Headlamp Housing Mount (FLHT)
2. Gently pull out headlamp assembly far enough to disconnect wiring.
3. Remove wire connector at the back of the headlamp bulb.
4. Remove three screws (3) that secure retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for kit installation.
FLHR Models
NOTE
Remove the entire mounting ring assembly (with headlamp) from the nacelle.
1. See Figure 3. Remove and save Phillips screws (1) that secure mounting ring assembly (2) to nacelle.
2. Gently pull assembly out far enough to disconnect wiring.
1Phillips screw (7)
2Mounting ring assembly
3Screw (3)
4Retaining ring
5Hole (not used)
Figure 3. Headlamp Housing Mount (FLHR)
3. Remove wire connector at the back of the headlamp bulb.
4. Remove three screws (3) securing the retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for installation.
INSTALLATION
Most FLHT and FLHR models have a headlamp harness with a three-way connector that plugs into the original equipment (OE) headlamp. The harness in this kit will connect the OE headlamp harness to the new headlamp in this kit.
Certain 2010 and earlier CVO models have a headlamp harness with two black two-way connectors that plug into separate high and low beam lamps. On those models:
  • Cut the black connector from the high beam (black and white) leads on the OE harness.
  • Cut the high beam (black and white) leads and gray connector from the kit harness.
  • Splice the two white leads per the instructions in the service manual appendix. Splice the two black leads in the same manner.
FLHT Models
1. See Figure 6. Connect wire harness (3) to headlamp assembly (1). The wire connector with one black and one yellow lead connects to the upper (low beam) bulb ( Figure 4 , Item 6). The connector with one black and one white wire connects to the lower (high beam) bulb ( Figure 4 , Item 7).
2. Install headlamp assembly (1) into mounting ring assembly (2). Note that the three alignment tabs on the back of the headlamp engage onto the three alignment pockets in the mounting ring assembly.
1Retaining ring
2Screw
3Mounting ring assembly
4Phillips screw (7)
5Hole (not used)
6Low beam bulb
7High beam bulb
Figure 4. Headlamp Housing Mount (Dual Bulb)
3. See Figure 4. Install retaining ring (1) and three screws (2) previously removed to secure headlamp assembly to mounting ring assembly (3).
4. See Figure 6. Hold headlamp assembly (1) close to opening in fairing and connect wire harness (3) to motorcycle harness connector.
5. Fold wire harness assembly and bundle using cable strap (5). This helps to eliminate the possibility of the wire harness rattling against the headlamp.
6. Position and align headlamp assembly to fairing.
7. See Figure 4. Install TORX screws (4) previously removed to secure mounting ring assembly (3) to fairing. Tighten screws securely.
FLHR Models
  1. See Figure 6. Connect wire harness (3) to headlamp assembly (1). The wire connector with one black and one yellow lead connects to the upper (low beam) bulb ( Figure 4 , Item 6). The connector with one black and one white wire connects to the lower (high beam) bulb ( Figure 4 , Item 7).
  2. Install headlamp assembly (1) into mounting ring assembly (2). Note that the three alignment tabs on the back of the headlamp engage onto the three alignment pockets in the mounting ring assembly.
  3. See Figure 4. Install retaining ring (1) and three screws (2) previously removed to secure headlamp assembly to mounting ring assembly (3).
  4. See Figure 6. Hold headlamp assembly (1) close to opening in nacelle and connect wire harness (3) to motorcycle harness connector.
  5. Fold wire harness assembly and bundle using cable strap (5). This helps to eliminate the possibility of the wire harness rattling against the headlamp.
  6. Position and align mounting ring assembly (2) to nacelle.
  7. See Figure 4. Install new washers ( Figure 6 , Item 4) from the kit onto the threads of the Phillips screws (4) previously removed, and secure the mounting ring assembly (3) to the nacelle. Tighten the screws securely.
FINAL ASSEMBLY
1. See Figure 5. Install chrome ring (1) and Phillips screw (2) previously removed.
NOTE
Verify that the ignition key switch is in the OFF position before installing the main fuse or attaching the battery cables.
2. Models with main fuse: Refer to the service manual and follow the instructions to install the main fuse. Proceed to step 5. Models with main circuit breaker:
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)
3. Refer to the service manual and follow the instructions to attach the battery cables (positive cable first). Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals.
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)
4. Refer to the service manual, and follow instructions to install the seat
5. ALL models: Adjust headlamp. Refer to the service manual.
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. Test headlamp for proper operation.
1Chrome ring
2Phillips screw
Figure 5. Install Headlamp Chrome Ring
SERVICE PARTS
Figure 6. Service Parts: Dual-Bulb Halogen Headlamp Kit
Table 1. Service Parts: Dual Bulb Halogen Headlamp Kit
Item
Description (Quantity)
Part Number
1
Halogen headlamp assembly (includes Item 3)
73271-11
2
Mounting ring assembly
68124-04B
3
Wire harness
73272-11
4
Washer (8) (FLHR only)
6717
5
Cable strap (2)
10006
Items mentioned in text, but not included in kit:
A
High beam harness connector (Blk/White wire on harness)
B
Low beam harness connector (Blk/Yellow wire on harness)
C
Low beam replacement bulb (Not Shown)
68881-01
D
High beam replacement bulb (Not Shown)
67717-01