INSTRUCTIONS - Harley
Contents
1. clutch lever by reversing step c Part No 68971 98A 69728 01 69723 XX Date 5 05 SMOTORZ M4 Service Parts Headlamp Visor Kits DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER Headlamp visor Not sold separately Gasket not shown 68134 97 Headlamp mounting block 67627 97 Screws buttonhead 5 4363 Visor bracket 90338 01 Washer 5 6424 Screw hex head mounting block 4722 Note Note Item 2 headlamp mounting block and item 7 hex head Place gasket around interior edge of headlamp visor mounting block screw are only used on 2005 and earlier opening models J01983 2 of 22. SMOTOR HARLEY DAVIDSON WY Kit Number 68971 98B is designed to fit 1984 1999 FXST FXSTC models Kit Number 69728 01 is designed to fit 1991 2005 FXDWG models Will not fit FXSTB models Kit Number 69723 XX is designed to fit 1991 2005 FXD FXDC FXDWG and 2006 and later FXDL FXDB and FXD models NOTE A Service Manual for your motorcycle is available from your Harley Davidson Dealer J01983 General See Service Parts illustration for kit contents Installation 1 See Service Parts illustration Install the edge gasket 4 to the headlamp visor 1 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 the gasket into place finishing with the seam top 2 See Figure 1 Remove headlamp assembly from motorcycle according to Service Manual instructions Save all hardware for reinstallation except mounting block 1 and screw 2 as shown These may be stored for use without the Headlamp Visor in place NOTE Take care while removing headlamp not to scratch any chrome surfaces 3 See Figure1 For 2005 and earlier models Replace existing mounting block with mounting block from kit 2 and secure with screw 7 as shown The mounting block should be positioned with the through hole positioned forward and to the front as shown Leave loose until Step 4 is completed 4 Position visor bracket 3 on back of head
3. lamp Secure headlamp to mounting block 2 using existing bolt washers and nut removed in Step 2 Align headlamp using procedure in appropriate Service Manual 5 See Service Parts Illustration Attach the headlamp visor 1 to the bracket with the 5 screws 5 and 5 washers 6 as shown and tighten to 40 in Ibs 4 5 N m NOTE If the clutch cable is rubbing on the headlamp visor proceed to Step 6 6 See Figure 2 Relocate clutch cable to the inside of the handlebars as shown in illustration as follows 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 INSTRUCTIONS REV 5 05 2005 Kit Number 68971 98B 69728 01 and 69723 XX HEADLAMP VISOR KIT i01272 Si A g el 1 Mounting block 2 Screw 1 Clutch cable 2 Handlebar Figure 2 New Clutch Cable Routing i00716 1 Clutch cable free play 1 16 1 8 inch 1 6 3 2 mm Figure 3 Clutch Cable Adjustment 1 of 2 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 Reroute clutch cable to the inside of the handlebars as shown in Figure 2 and reconnect clutch cable to
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