EMERGENCY HEADLAMP AND STROBE KIT - Harley
Contents
1. MOTOR HARLEY DAVIDSON UY J05531 INSTRUCTIONS REV 2013 08 20 EMERGENCY HEADLAMP AND STROBE KIT FOR FLHP FLHTP POLICE MODELS GENERAL Kit Number 67700222 Models For model fitment information see the Harley Davidson Police and Fleet Motorcycle catalog or the Police and Fire Rescue section of www harley davidson com English only NOTE This accessory must be removed when vehicle is sold for non police use Follow all applicable federal state and local regulations when changing to a civilian vehicle Installation Requirements An Ultratorch UT 100 Part No HD 39969 Robinair Heat Gun Part No HD 25070 with Heatshrink Attachment Part No HD 41 183 or other suitable radiant heating device is required for proper installation of this kit Electrical Contact Lube H D Part No 99861 02 or equivalent is required after battery disconnection This item is available from a Harley Davidson dealer WARNING 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 00333a NOTE This instruction sheet refers to service manual information A service manual and a Police Model service manual supplement for this year model mot2. necessary Fit the headlamp door spring into the slot at the top of the headlamp mounting ring Install the chrome headlamp door Insert the Phillips head screw at the bottom Tighten to 9 18 in Ibs 1 0 2 0 Nm 5 of 9 Installation 2013 Earlier FLHTP Models 1 See the service manual to remove the outer fairing and windshield NOTE See Figure 10 The power supply mounts to the steel plate 2 directly under the plastic radio mounting box 1 immediately to the right of the steering head e The fir tree style wire retainer must be removed from the steel plate in order to use the hole for mounting the power supply e The hole in the steel plate is slightly larger than the hole in the power supply mount e When installing the power supply it is not an exact fit Manipulating the power supply into various positions will be necessary to obtain the optimal alignment and position Steel plate Locknut Power supply Strobe harness 2 e Even if the overall fit appears less than perfect the power supply becomes secure when the hardware is fully tightened Figure 11 Mount the Power Supply 2013 Earlier FLHTP Models is07139 6 See the service manual to install and crimp the ring ter minal Figure 15 Item 7 from the kit to the end of the black power supply ground wire 7 See Figure 12 Hold the power supply 1 and securing screw in place Remove the locknut 2 Place the black ground wire 3 r
3. supply as necessary 3 of 9 1 Headlamp assembly 2 Strobe power supply harness connector 2 Figure 6 Install Strobe Harnesses to Headlamp 2013 Inst 1 Earlier FLHP Models See Figure 6 Get the new headlamp assembly 1 from the kit Plug the vehicle harness headlamp connector into the new headlamp bulb Plug each three pin connector from the strobe lamps into one of the strobe power supply har ness connectors 2 See Figure 2 Get the seven Phillipos head screws removed earlier and seven new washers from the kit Align the headlamp assembly to the opening in the nacelle Install with the screws and washers Tighten the mounting screws to 9 18 in Ibs 1 0 2 0 Nm Fit the headlamp door spring into the slot at the top of the headlamp housing See Figure 1 Install the chrome headlamp door 1 Insert the Phillipos head screw 2 at the bottom Tighten to 9 18 in Ibs 1 0 2 0 Nm allation 2014 Later FLHP Models Remove the seat and fuel tank per the service manual NOTES Electrical connectors are identified in the service manual by the numbers and letters shown here within brackets See the service manual appendix Cut the high beam C38HI and low beam C38LO headlamp connector wires as close to the connectors as possible Cut the high beam C38HI and low beam C38LO head lamp connectors from the vehicle harness See Figure 15 Obtain the FLHP headlamp jumper harness 16 from the ki
4. 2 Pursuit flasher 3 Connector 69B 4 Red power supply wire 5 Cut gray black wire from connector 69B 6 Sealed splice connector Figure 13 Pursuit Flasher and Flasher Connector 2013 10 11 12 13 14 15 16 17 Earlier FLHTP Models NOTES The pursuit flasher is located to the right of the radio mounting box secured to the fairing by a cable strap Electrical connectors are identified in the service manual by the numbers and letters shown here within brackets Locate the pursuit flasher 2 and the three way connector 69B 3 plugged into the flasher Unplug the connector Select the gray black wire 5 in the connector Cut the wire about 4 5 in 100 125 mm from the connector Get the sealed splice connector 6 from the kit See the service manual appendix to splice the red power supply wire 4 to the two gray black wire ends 5 Plug the three way connector into the flasher Carefully tuck the wiring in and around the surrounding wiring Use cable straps not provided to secure all wiring in place Make sure the wiring is not pulled or damaged when the fairing is installed Use cable straps to secure the power supply as necessary See the service manual to install the outer fairing and windshield Get the new headlamp assembly from the kit Reach in through the headlamp opening in the fairing Retrieve the headlamp connector and the two strobe harnesses coming from the power
5. ation 2014 Later 14 15 18 19 20 21 22 23 24 FLHP Models Attach the black wire ring terminal to the left frame ground stud Locate the pursuit flasher behind the left side cover and the three way connector C69B plugged into the flasher Unplug the connector from the flasher Select the blue black wire in the connector Strip back the conduit Cut the blue black wire about 2 3 in 50 75 mm from the connector Get the sealed splice connector from the kit See the ser vice manual appendix to splice the red power supply wire to the two blue black wire ends Plug the three way connector into the flasher Bring the strobing headlamp into position Plug in the two strobe connectors Plug the headlamp harness into the headlamp bulb Secure the strobing headlamp wiring to the existing wiring with cable straps not supplied Make sure that there is sufficient wire length that the wiring does not pull tight when handlebar is turned fully to left or right fork stops See Figure 15 Install the headlamp 1 to the mounting ring 5 with the retaining ring 11 and three screws 12 a Make sure that the strobes are fully engaged in the light assembly b Make sure that the circular pads are pressed against strobe retention ears c Make sure that there is clearance between the power supply housing and the headlight cone Adjust the headlight alignment screws to gain more clearance if
6. eadlamp connector and the two strobe harnesses coming from the power supply Plug the two strobe connectors into the strobe bulbs Plug the headlamp harness into the headlamp bulb Install the headlamp assembly to the opening in the fairing with the four screws removed earlier Tighten the screws to 22 32 in Ibs 2 5 3 6 Nm Position the chrome headlamp door assembly onto the headlamp mounting ring with the screw hole in the five o clock position Rotate the assembly clockwise to engage the spring tab with the slot in the headlamp mounting ring J05531 Secure the headlamp door with the OE screw Tighten the screw to 9 18 in Ibs 1 0 2 0 Nm RETURN TO SERVICE NOTE Verify that the ignition key switch is OFF before installing the main fuse or attaching the negative battery cable 1 Models with main fuse See the service manual to install the main fuse Models with main circuit breaker See the service manual to attach the negative battery cable Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals Test the headlamp and strobe lamps for proper operation If installed properly the strobes will turn on and flash with the front emergency lamps 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 3 4 See the service
7. h two 10 screws 4 and flat washers 5 from the kit Make sure that the power supply is positioned at the bottom of the screw slots 2 Tighten the screws to 20 30 in Ibs 2 3 3 4 Nm Plug the power input harness into the power supply and route the wires out the rear of the nacelle See Figure 9 Mount the power supply and bracket assembly 1 behind the two screw flanges of the nacelle Install two 10 screws 3 and flat washers 4 a through the headlamp mounting ring 5 b through the nacelle flanges and c into the tapped holes in the bracket 2 Tighten the screws 3 to 20 30 in Ibs 2 3 3 4 Nm Route the power supply cable down the right side of the vehicle frame wire trough Make sure that there is sufficient wire length The cable must not pull tight when handlebar is turned fully to left or right fork stops Strip the power cable covering at the rear of the wire trough to route a the black ground wire to the left frame ground stud and b the red power wire into the left side cover area The white wire is used to change the strobing pattern It can be routed as desired See the service manual to install and crimp the ring ter minal from the kit to the end of the black power supply ground wire J05531 1 2 3 10 screw 2 4 5 Headlamp mounting ring Mh Power supply and bracket assembly Power supply bracket 10 flat washer 2 Figure 9 Headlamp Power Supply Install
8. ing terminal 4 onto the screw threads Insert the screw through the steel plate and power supply Install the locknut onto the screw threads Tighten securely wk 8 See Figure 13 Route the red power supply wire 4 upward and toward the right side of the plastic radio mounting box 1 1 Plastic radio mounting box 2 Steel plate 3 Hole in steel plate Figure 10 Locate the Steel Mounting Plate 2013 Earlier FLHTP Models 2 Locate the steel plate 2 to which the power supply mounts Remove the black plastic fir tree style wire retainer from the hole 3 in the plate 3 See Figure 15 Get the power supply 6 screw 9 and locknut 10 from the kit Position the power supply over the steel plate as shown in Figure 11 Align the mounting hole on the left side of the power supply with the hole in GE i AIN N f K L s the steel plate 1 Power supply 4 Install the screw from the opposite side under the fairing 2 Locknut cap through the steel plate 1 and power supply 3 3 Black ground wire mount Install the locknut 2 but do not fully tighten now 4 Ring terminal 9 Route the two strobe power supply harnesses 4 the red Figure 12 Install Ground Wire Ring Terminal 2013 Earlier power wire and the black ground wire away from the power supply and free of other wiring in the fairing J05531 FLHTP Models 6 of 9 is07142 1 Radio mounting box
9. l vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b NOTE e 2007 later vehicles equipped with security siren With security fob present turn ignition switch ON After system is disarmed turn ignition switch OFF IMMEDIATELY remove the main fuse per the service manual e 2006 earlier vehicles equipped with security siren Disarm the siren with the key fob or security code See the service manual to remove the main fuse e Vehicles WITHOUT security siren See the service manual to remove the main fuse 1 of 9 Please dispose of materials responsibly ALL Vehicles With Main Fuse WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 See the service manual to remove the main fuse ALL Vehicles With Main Circuit Breaker WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 See the service manual to remove the seat Disconnect the negative black battery cable from the negative battery terminal Retain all seat mounting hardware N ALL models Turn the ignition key switch OFF unless already done REMOVAL 1 See Figure 1 Remove the Phillips head screw 2 at the bottom of the chrome headlamp door 1 2014 later FLHTP models Rotate the headlamp d
10. lation for the specific model Installation 2013 Earlier FLHP Models NOTE The power supply mounts to a steel plate inside the nacelle e Remove the fir tree style wire retainer from the steel plate in order to use the hole for mounting the power supply e The hole in the steel plate is slightly larger than the hole in the power supply mount e When installing the power supply it is not an exact fit Manipulate the power supply into various orientations to find the optimal alignment and position e Even if the overall fit appears less than perfect the power supply becomes secure when the hardware is fully tightened 1 Steel plate 2 Locknut 3 Power supply 4 Strobe harness Figure 4 Mount the Strobe Power Supply 2013 Earlier FLHP Models 1 See Figure 4 Locate the steel plate 1 to which the power supply 3 is mounted Remove the black plastic fir tree style wire retainer from the hole in the plate 2 See Figure 15 Get the power supply 6 screw 9 and locknut 10 from the kit Position the power supply over the steel plate see Figure 4 Align the upper power supply mounting hole with the hole in the steel plate J05531 3 Install the screw up through the steel plate and power supply mount Install the locknut 2 but do not fully tighten now Route the two strobe power supply harnesses the red power wire and the black ground wire away from the power supply and free of the other wiri
11. manual to install the fuel tank if removed Install the seat Align the headlamp per the service manual 8of9 SERVICE PARTS is07832 Figure 15 Service Parts Emergency Headlamp and Strobe Kit Table 1 Service Parts Item Description Quantity Part Number 1 Headlamp assembly includes Item 2 67636 02 2 e Boot headlamp bulb Not sold separately 3 Bulb headlamp H4 Performance 67074 02 4 Bulb strobe 2 with separate connector 68692 02 5 Mounting ring assembly strobing headlamp Not sold separately 6 Power supply 90051 02 7 Ring terminal 16 22 AWG for 1 4 in 6 4 mm diameter stud 9858 8 Sealed splice connector blue 70586 93 9 Screw TORX button head 10 24 x 1 2 in 12 7 mm long 2478 10 Lock nut 10 24 with nylon insert 7624 11 Retaining ring headlamp 67726 08 12 Screw retaining ring 3 67721 48 13 Washer 7 6717 14 Bracket power supply Not sold separately 15 Flat washer 10 4 6716 16 Headlamp jumper harness FLHP models Not sold separately 17 Headlamp jumper harness FLHTP models Not sold separately 18 Power input harness Not sold separately J05531 9 of 9
12. ng within the nacelle 5 Get the ring terminal 7 from the kit See the service manual appendix to install and crimp the terminal to the end of the black power supply ground wire 6 See Figure 5 Remove the screw 2 and locknut loosely securing the power supply to the steel plate 1 Allow the power supply to rest in the nacelle Route the black ground wire 3 with ring terminal to the back of the steel plate Place the ring terminal onto the screw threads Insert the screw through the steel plate and power supply Install the locknut onto the screw threads Tighten securely 1 Steel plate 2 Screw and ring terminal 3 Black ground wire Figure 5 Install Ground Wire Ring Terminal 2013 Earlier FLHP Models NOTE Electrical connectors are identified in the service manual by the numbers and letters shown here within brackets 7 Locate the white two way pursuit switch connector 73 inside the nacelle Pull the connector and wiring away from the other wiring in the nacelle 8 Locate the gray violet wire in cavity 1 of the connector Cut the wire about 2 3 in 50 76 mm from the connector 9 Get the sealed splice connector Figure 15 Item 8 from the kit See the service manual appendix to splice the red power supply wire to the two gray violet wire ends 10 Carefully tuck the red and gray violet wiring back into the nacelle in and around existing wiring Use cable straps not provided to secure the power
13. oor counterclockwise Remove the headlamp door All other models Remove the headlamp door All models Save the screw for later installation NOTE Remove the entire lamp bucket assembly including headlamp from the nacelle FLHP models or fairing FLHTP models 2 FLHP Models See Figure 2 Remove the Phillips head screws 1 securing the headlamp bucket to the nacelle FLHTP Models See Figure 3 Remove the four TORX head screws 1 securing the headlamp bucket to the fairing ALL Models Gently pull the headlamp bucket out far enough to disconnect the wiring Squeeze the two external tabs if present to remove the wire connector at the back of the headlamp bulb Save the screws for later installation Remove and discard the headlamp bucket J05531 is07133 Ker 1 Chrome headlamp door 2 Phillips head screw 1 Phillips head screws 2 No screw this location 2013 earlier Figure 2 Headlamp Housing Mount FLHP 1 TORX head screw 4 is07135 Figure 3 Headlamp Housing Mount FLHTP 2 of 9 INSTALLATION WARNING The strobe lamp power supply is a source of high voltage Inadequate safety precautions can result in death or ser ious injury 00097b e Do not perform any service while the system is operating e Wait 10 minutes after disconnecting the unit from the power source before servicing or troubleshooting on the power supply or system Proceed to Instal
14. orcycle are required for this installation These manuals are available from a Harley Davidson dealer Kit Contents See Figure 15 and Table 1 NOTE Use only the correct replacement headlamp bulb Part No 67074 02 and replacement strobe lamp bulb Part No 68692 02 Use of any other lamp bulbs may produce improper light levels J05531 sMany Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled PREPARATION 2014 later FLHP models ONLY These models are equipped from the factory with a dual halogen headlamp When switched to high beam BOTH the low beam and high beam lamps are lit The strobing headlamp requires the low beam lamp to turn off when the high beam switch is activated 1 Use the following procedure to program the vehicle body control module to operate the strobing headlamp correctly a Turn the ignition switch ON but do not start the motorcycle b Press and hold the LEFT TURN switch button Press the Stealth Mode toggle switch 5 times within 5 seconds c Verify that the low beam lamp is off when the high beam lamp is lit Verify that the high beam lamp is off when the low beam lamp is lit If not repeat Step 1b 2 The headlamp mode change procedure in Step 1c can also be made using the Digital Technician diagnostic tool Changing back to dual halogen mode can ONLY be done using Digital Technician ALL Models WARNING To prevent accidenta
15. supply Plug the vehicle harness headlamp connector into the new headlamp bulb Plug each three pin connector from the strobe lamps into one of the strobe power supply har ness connectors See Figure 3 Get the four TORX head screws removed earlier and four new washers from the kit Align and install the headlamp assembly to the opening in the fairing Tighten the mounting screws to 22 32 in lbs 2 5 3 6 Nm J05531 18 Fitthe headlamp door spring into the slot at the top of the headlamp housing See Figure 1 Install the chrome headlamp door 1 Insert the Phillips head screw 2 at the bottom Tighten the screw to 9 18 in Ibs 1 0 2 0 Nm Installation 2014 Later FLHTP Models 1 Remove the windshield outer fairing seat and fuel tank per the service manual See Figure 14 Remove the TORX head screw 3 on the inner fairing support bracket 2 in the location shown Position and mount the power supply 1 to the bracket with the screw Tighten to 25 35 in Ibs 2 8 4 0 Nm 1 Power supply 2 Inner fairing support bracket 3 TORX head screw 4 Separate accessory not part of this kit Figure 14 Headlamp Power Supply Installation 2014 Later FLHTP Models Plug the power input harness into the power supply Route the power supply cable down the right side of the vehicle frame wire trough Make sure that there is sufficient wire length that the cable does not pull tight when handlebar is turned fully
16. t J05531 See the service manual appendix to splice the vehicle headlamp wires to the jumper harness a Blue white high beam power wire to jumper harness white wire b Black high beam ground wire to one jumper harness black wire c Blue yellow low beam power wire to jumper harness yellow wire d Black low beam ground wire to remaining jumper harness black wire NOTE Make sure that the strobe bulbs 3 do not fall out of the headlamp housing while handling the headlamp assembly 1 5 6 WUE is07825 Disassemble the strobing headlamp from the mounting ring 5 by removing the three retaining ring screws 12 Retain the screws See Figure 7 Remove two well nuts from the headlamp nacelle 2 at the locations marked 1 Install the strobing headlamp mounting ring 3 to the headlamp nacelle with six original equipment OE 6 screws 4 removed earlier and six 6 flat washers 5 from the kit Tighten the screws to 9 18 in Ibs 1 0 2 0 Nm 1 2 Headlamp nacelle 3 Strobing headlamp mounting ring 4 OE 6 screw 6 5 6 flat washer 6 Figure 7 Strobing Headlamp Mounting Ring 2014 Later FLHP Models 4 of 9 af 2 Power supply Screw slot 2 Bracket 10 screw 2 10 flat washer 2 Figure 8 Strobing Headlamp Power Supply 2014 Later 10 11 12 13 FLHP Models See Figure 8 Mount the power supply 1 to the bracket 3 as shown wit
17. to left or right fork stops Strip the power cable covering at the rear of the wire trough to route a the black ground wire to the left frame ground stud and b the red power wire into the left side cover area The white wire is used to change the strobing pattern It can be routed as desired See the service manual to install and crimp the ring ter minal from the kit to the end of the black power supply ground wire Attach the black wire ring terminal to the left frame ground stud Locate the pursuit flasher behind the left side cover and the three way connector C69B plugged into the flasher Unplug the connector from the flasher Select the blue black wire in the connector Strip back the conduit Cut the blue black wire about 2 3 in 50 75 mm from the connector 7 of 9 10 See Figure 15 Obtain the FLHTP headlamp jumper har Get the sealed splice connector from the kit See the ser vice manual appendix to splice the red power supply wire to the two blue black wire ends Plug the three way connector into the flasher ness 17 from the kit Plug the harness into the vehicle headlamp connector C38B Using cable straps not supplied to secure all power supply wiring Make sure that the wires are not pinched and will not chafe Install the outer fairing and windshield per the service manual Get the strobing headlamp assembly 1 from the kit Reach in through the headlamp opening and retrieve the h
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