BILLET HEADLAMP WITH SHORT/TALL MOUNTS

Transcription

1 -J099 REV BILLET HEADLAMP WITH SHORT/TALL MOUNTS GENERAL Kit Number 9-0, 9-0 Models Kit 9-0 is a -/ inch headlamp and kit 9-0 is a -/ inch headlamp. Both kits will fit the models listed in Table. Table. Short and Tall Mount Kits Kits Short Mount Kit 9-0 Tall Mount Kit 9-0 Models FXSTC, 99- Later FXST/B, and 000-Later FXSTD; FXDWG 99-Later XL 00C and 99-Later XL C; All 00 Dyna Models; FXR// REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (000a). Disconnect negative (-) battery cable.. Remove fuel tank. Refer to FUEL TANK in Service Manual.. Disconnect -place headlamp connector [] from main wire harness. Headlamp connector is located under fuel tank on left side. is0 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 9-0 or 9-0 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. The rider's safety depends 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. (00a) 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,Table and Figure, Table.. Screw. Washer. Nut. Lockwasher. Washer (). Screw. Mounting block. Headlamp assembly Figure. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) All Softails (except FXSTD) complete steps through. For FXSTD models complete steps through 9. -J099 Many Harley-Davidson Parts & Accessories are made of plastics and metals which can be recycled. Please dispose of materials responsibly. of 0

2 . All Softails (except FXSTD): See Figure. Remove screw () and washer () from stem and bracket. Discard screw but save washer for later use. is00. Remove and discard mounting block () and headlamp assembly ().. FXSTD models: See Figure. Remove screw () and washer () from stem and bracket. Save screw and washer for later use.. Remove and discard nut (), washers (), and screw ().. Remove and discard mounting block () and headlamp assembly (). is0. Cable strap. Wire harness Figure. Dyna Service Loop (00-Earlier). 00-Earlier FXDWG: See Figures and. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 00-Later FXD: See Figure. Remove cover under top frame tube, then pull connector out from opening under tube.. Disconnect -place headlamp connector [] from main wire harness. is0. Screw. Washer. Acorn nut. Washer (). Screw. Mounting block. Headlamp assembly Figure. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models. Remove seat following the instructions in the Service Manual.. Disconnect negative (-) battery cable.. Remove fuel tank. Refer to FUEL TANK in Service Manual.. Frame tube. Plug Figure. Dyna Top Frame Tube (00-Earlier) -J099 of 0

3 is0 is09,. Frame tube. Cover. Plug Figure. Dyna Top Frame Tube (00-Later). See Figure. Remove screw () and washer () from stem and bracket. 00-Earlier FXDWG: Discard screw but save washer for later use. 00-Later FXD: Save screw and washer for later use.. Remove and discard nut (), washers (), and screw ().. Remove and discard mounting block () and headlamp assembly (). Remove Headlamp and Mounting Bracket for Sportster Models. Remove seat following the instructions in the Service Manual.. 00-Earlier: Disconnect negative (-) battery cable. 00-Later: Remove maxi-fuse. Refer to MAXI-FUSE in Service Manual.. Remove fuel tank. Refer to FUEL TANK in Service Manual.. Disconnect -place headlamp connector [] from main wire harness. Headlamp connector is located under fuel tank.. See Figure. Remove screw () and washer () from stem and bracket. Save screw and washer for later use.. Remove and discard nut (), washers (), and screw ().. Remove and discard mounting block () and headlamp assembly ().. Screw. Washer. Nut. Washer (). Screw. Mounting block. Headlamp assembly, Figure. Sportster Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for FXR Models. Remove seat following the instructions in the Service Manual.. Disconnect negative (-) battery cable.. Remove fuel tank. Refer to FUEL TANK in Service Manual.. Disconnect -place headlamp connector [] from main wire harness. Headlamp connector is located under fuel tank on left side.. See Figure. Remove screw () and washer () from stem and bracket. Save screw and washer for later use.. Remove and discard nut (), washers (), and screw ().. Remove and discard mounting block () and headlamp assembly (). -J099 of 0

4 is00 is0 9. Screw. Washer. Nut. Washer (). Screw. Mounting block. Headlamp assembly Figure. FXR Headlamp Assembly with Mount INSTALLATION Install Billet Headlamp with Short Mount. Softail and FXDWG Models: See Figure. Loosely install vertical adjusting screw () from kit and washer () previously saved. 000-Later FXSTD Models: See Figure. Loosely install vertical adjusting screw () and washer () previously saved.. Loosely install mounting block () and billet headlamp () using horizontal adjusting screw (), washers (), lockwasher (), and acorn nut ().. Screw. Washer. Mounting block, short. Headlamp assembly. Screw. Washer (). Lockwasher. Acorn nut 9. Mounting block, tall Figure. Billet Headlamp Assembly with Short/Tall Mounts Install Billet Headlamp with Tall Mount. See Table and Figure. Loosely install vertical adjusting screw () and washer () previously saved.. Loosely install mounting block (9) and billet headlamp () using horizontal adjusting screw (), washers (), lockwasher (), and acorn nut ().. Check headlamp for proper height and lateral alignment. Refer to Headlamp Alignment section in Instruction Sheet. Connect Headlamp Wiring Models With -Place Amp Multilock Connector:. Locate main harness pin housing.. Insert socket housing of billet headlamp into pin housing of main harness. -J099 of 0

5 is0 is0. Black ground wire. Bulb connector. Wire from connector to terminal. Ring terminal Figure 9. Clip Black Ground Wire Models Without -Place Amp Multilock Connector: Older chassis ground models, complete steps and.. See Figure 9. Clip black ground wire () inside new billet headlamp close to the bulb connector (). Refer to REPLACE LAMP ASSEMBLY AND BULB for procedures to disassemble billet headlamp. There are two black wires exiting the bulb. Be careful not to clip the wire that is grounded to the internal housing with ring terminal.. Pull the long black wire out of the sleeving and discard.. See Figure 0. Remove -/ inch (. mm) of black jacket () at a convenient location from headlamp wire harness ().. Using wire cutters, remove the headlamp socket housing (). Use care not to cut the insulation on the three wires inside the headlamp wire harness.. Butt splice wires of billet headlamp to wires of main harness. Also refer to SEALED BUTT SPLICE CON- NECTORS in Service Manual.. Strip /-inch (9. mm) of insulation off the ends of the headlamp wires.. See Figure. Insert headlamp wires into butt splice connector until the stripped ends are housed inside the metal insert ().. Crimp the wires () within the connector using suitable crimping tool.. Black jacket. Headlamp wire harness. Socket housing. Headlamp wires (). Bulb connector Figure 0. Remove Black Jacket, Socket Housing, and Strip Wires 9. Repeat steps on other side of butt splice connector for main harness wires. Stagger the spices so that the butt splice connectors are spaced at different positions along the length of the wires. is0. Metal insert. Crimp wire ends. Melted sealant after heating/cooling Figure. Install Sealed Butt Splice Connectors -J099 of 0

6 Be sure to follow manufacturer's instructions when using the UltraTorch UT-00 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00a) Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury. Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed. Always keep hands away from tool tip area and heat shrink attachment. 0. Using the UltraTorch UT-00 (999) or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the meltable sealant exudes out both ends of the connector.. Heat the center of the butt splice () until the crimp indentations disappear and the tubing assumes a smooth cylindrical appearance.. Slide section of black jacket previously removed over butt spliced wires and secure with clips. Headlamp Alignment. Stand motorcycle upright with both tires resting on floor, and with front wheel held in straight alignment (directly forward).. Sotail and Dyna Models: Turn ignition switch to ON position. Sportster Models: Turn ignition/light switch to IGNITION position. FXR Models: Turn ignition/light switch to IGNITION position.. See Figure. Set handlebar headlamp switch to high beam position. 9. Check light beam for alignment as follows: a. The main beam, 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 and left of center. 0. Tighten vertical adjusting screw and horizontal adjusting nut to -0 ft-lbs (.9-0. Nm). is0 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. (0000b). Verify correct front and rear tire pressure. Refer to TIRES AND WHEELS in Service Manual.. Place motorcycle on level floor (or pavement) in an area with minimum light.. Position motorcycle ft (. m) away from a screen or wall. Measure the distance from directly below the front axle to the base of the screen/wall.. See Figure, Letter (A). Draw a horizontal line inches (0.9 m) above floor on screen wall. is0 Figure. Headlamp Alignment. Load vehicle with rider, passenger (if normally present) and any cargo. Weight will compress vehicle suspension slightly. A Final Assembly Softail and FXR Models Figure. High Beam Setting. Install fuel tank. Refer to FUEL TANK in Service Manual.. Connect negative (-) battery cable. Dyna Models. Install fuel tank. Refer to FUEL TANK in Service Manual.. Install seat following the instructions in the Service Manual.. Connect negative (-) battery cable. FXR Models. Install fuel tank. Refer to FUEL TANK in Service Manual.. 00-Earlier models: Connect negative (-) battery cable.. 00-Later models: Install maxi-fuse. Refer to MAXI-FUSE in Service Manual. -J099 of 0

7 REPLACE LENS ASSEMBLY AND BULB 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. (0009a) You can also use latex gloves to remove/install the chrome trim ring. This will enable you to grip the chrome trim ring and will not mark the finish. is0 Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Grab the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (000a) Handle bulb carefully and wear eye protection. Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (000b) You do not need to remove billet headlamp from motorcycle to replace lamp assembly and bulb. Disassembly. All models (except 00-Later Sportster): Disconnect negative (-) battery cable. 00-Later Sportster models: Remove maxi-fuse. Refer to MAXI-FUSE in Service Manual.. Using a 0/0 isopropyl alcohol/water solution, thoroughly clean the billet headlamp and surface of the chrome trim ring. Let dry completely.. See Figure. Using /-inch allen wrench, remove outer set screw at bottom of headlamp shell. Figure. Place Two-Sided Tape on Chrome Trim Ring is0 is0 Figure. Chrome Trim Ring (two-sided tape shown). See Figure. Place fingers on two-sided tape and remove chrome trim ring (rotate counterclockwise) and O- ring.. See Figure. Using service tool, remove inner ring (rotate counterclockwise) and rubber O-ring.. See Figure. Unplug lamp assembly () from bulb connector () and remove from shell. Figure. Allen Wrench and Outer Set Screw. See Figure. Cut three / x -inch strips of two-sided tape and place at equal distance around the chrome trim ring. -J099 of 0

8 is0. See Figure. Plug lamp assembly () into wire harness connector (). Gently press lamp assembly into position inside headlamp shell.. See Figure. Using service tool, install inner ring (rotate clockwise) and rubber O-ring. Use care when installing ring to ensure proper threading into headlamp shell.. See Figure. Install chrome trim ring (rotate clockwise) and rubber O-ring. Remove strips of two-sided tape from ring if used. Use care when installing ring to ensure proper threading into headlamp shell.. See Figure. Using /-inch allen wrench, install outer set screw at bottom of headlamp shell. is00 is09 Figure. Service Tool and Inner Ring. Rubber boot. Lens assembly and bulb. Retaining clip Figure 9. Lens Assembly, Retaining Clip, and Rubber Boot. Lamp assembly. Bulb connector. Headlamp shell is0 Figure. Lamp Assembly and Bulb Connector. See Figure 9. Remove rubber boot () from back of lens assembly and bulb (). 9. Press ends of retaining clip () to unhook from notched retaining post, then pivot retaining clip back. 0. See Figure 0. Remove bulb () from lens assembly (). Assembly. See Figure 0. Fit replacement bulb () into lens assembly ().. See Figure 9. Pivot the retaining clip () over the bulb and press the ends into the retaining post.. Install rubber boot () into back of lens assembly ().. Bulb. Lens Assembly Figure 0. Lens Assembly and Bulb -J099 of 0

9 SERVICE PARTS is Figure. Service Parts: -/ Inch Billet Headlamp With Short/Tall Mounts Kit -/ Inch Billet Headlamp 9-0 Short Mount Kit 9-0 Tall Mount Kit 9-0 Table. Service Parts: -/ Inch Billet Headlamp With Short/Tall Mounts Item 9 0 Chrome trim ring Service tool, inner ring Inner ring Lens Assembly Bulb, dual filament V 0/W H Retaining clip Rubber boot Headlamp shell, chrome Headlamp wiring Description (Quantity) Set screw, #- x / in. (outer trim ring) Set screw, #- x / in. (nesting ring) Billet headlamp mount, short Capscrew, hex hd /- x -/ in. () (chrome); FXSTD models use quantity of one. Washer, flat / in () (chrome) Washer, lock / in (chrome) Nut, acorn /- (chrome) Billet headlamp mount, tall Note: This kit also includes item (quantity of one) and items through. Part Number T 90-90T 90-90T T -J099 9 of 0

10 is Figure. Service Parts: -/ Inch Billet Headlamp With Short/Tall Mounts Kit -/ Inch Billet Headlamp 9-0 Short Mount Kit 9-0 Tall Mount Kit 9-0 Table. Service Parts: -/ Inch Billet Headlamp With Short/Tall Mounts Item 9 0 Chrome trim ring Service tool, inner ring Inner ring Lens Assembly Bulb, dual filament V 0/W H Retaining clip Rubber boot Headlamp shell, chrome Headlamp wiring Description (Quantity) Set screw, #- x / in. (outer trim ring) Set screw, #- x / in. (nesting ring) Billet headlamp mount, short Capscrew, hex hd /- x -/ in. () (chrome); FXSTD models use quantity of one. Washer, flat / in () (chrome) Washer, lock / in (chrome) Nut, acorn /- (chrome) Billet headlamp mount, tall Note: This kit also includes item (quantity of one) and items through. Part Number T 90-90T 90-90T T -J099 0 of 0