MoCo Bullet Headlamp Install
Thread Starter
|
Banned
Joined: Mar 2010
Posts: 5,403
Likes: 7
From: Southwest Florida
MoCo Bullet Headlamp Install
I'm thinking about getting the Harley 'Bullet' headlamp Part #68593-06.
I want to install it myself and the pdf instruction sheet from the Harley website says you gotta take the gas tank off. So I go and check my trusty Service Manual and it looks like a PITA. Maybe not to those of you that have done it several times, but I'll be re-inventing the freaking wheel. As usual.
So while I'm in the SM I decide to check on 'headlight removal' and the SM says you can slide the gas tank back to get at the wires.
Hmmmm, sez I. Conflicting instructions. From Hardly Dangerous? Imagine that.
The biggest reason I want to know is that if I gotta remove the gas tank (which entails taking off the instrument panel, IIRC) then I'm gonna get my combo tach/speedo at the same time. If I don't, I'll wait. Money doesn't grow on trees in the Grendel household and the War Department don't wanna hear about getting a 2nd job to fund my Harley habit.
Also, if I gotta take the gas tank off, I gotta make a plan or two. Like maybe do it at my neighbor's house cause gas is gonna drip all over the floor of my garage. No big deal to me, but the afore-mentioned War Department will not be happy. Gas fumes give her migraines. I've never had a migraine but I understand they're no fun. So I try to be thoughtful of what gives her those nasties. Fumes of all kinds. Except fingernail polish remover doesn't seem to bother her. I make her go outside when she uses it cause I hate it. Go figure.
Oh yeah, I did several searches and read several threads that weren't really all that helpful.
Thoughts and tips would be appreciated.
I want to install it myself and the pdf instruction sheet from the Harley website says you gotta take the gas tank off. So I go and check my trusty Service Manual and it looks like a PITA. Maybe not to those of you that have done it several times, but I'll be re-inventing the freaking wheel. As usual.
So while I'm in the SM I decide to check on 'headlight removal' and the SM says you can slide the gas tank back to get at the wires.
Hmmmm, sez I. Conflicting instructions. From Hardly Dangerous? Imagine that.
The biggest reason I want to know is that if I gotta remove the gas tank (which entails taking off the instrument panel, IIRC) then I'm gonna get my combo tach/speedo at the same time. If I don't, I'll wait. Money doesn't grow on trees in the Grendel household and the War Department don't wanna hear about getting a 2nd job to fund my Harley habit.
Also, if I gotta take the gas tank off, I gotta make a plan or two. Like maybe do it at my neighbor's house cause gas is gonna drip all over the floor of my garage. No big deal to me, but the afore-mentioned War Department will not be happy. Gas fumes give her migraines. I've never had a migraine but I understand they're no fun. So I try to be thoughtful of what gives her those nasties. Fumes of all kinds. Except fingernail polish remover doesn't seem to bother her. I make her go outside when she uses it cause I hate it. Go figure.
Oh yeah, I did several searches and read several threads that weren't really all that helpful.
Thoughts and tips would be appreciated.
Thread Starter
|
Banned
Joined: Mar 2010
Posts: 5,403
Likes: 7
From: Southwest Florida
Bump.
No takers, huh?
C'mon guys, I just wanna know if anyone has had success sliding back the gas tank on a late model dyna to get to the wires for the headlight or if removing the gas tank is the best/only way.
One of my concerns is the crossover tube. Another is getting to the cover under the main frame and whether that's even necessary.
I'd appreciate any input.
No takers, huh?
C'mon guys, I just wanna know if anyone has had success sliding back the gas tank on a late model dyna to get to the wires for the headlight or if removing the gas tank is the best/only way.
One of my concerns is the crossover tube. Another is getting to the cover under the main frame and whether that's even necessary.
I'd appreciate any input.
Advanced
Joined: Mar 2010
Posts: 57
Likes: 0
From: Los Angeles
When I did my front turn signal relocation I managed to get to all the plugs with out completely removing the tank. Just unbolted everything thing and wiggled the tank back as far as it could go. Gotta be careful of the cross over line though. I read somewhere on here that they snap easy.
I'm no professional but it should be an easy job as long as you take your time.
I'm no professional but it should be an easy job as long as you take your time.
Grand HDF Member
Joined: May 2007
Posts: 3,553
Likes: 17
I installed a similar headlight. I cut the wires. Didn't go back under the tank for anything. All my connections are inside the bucket and are soldered/heat shrink wrapped. I know it's the the ideal way but my connections are sealed from the elements and are encased in the chrome bucket so I think it's damn fine the way it is and it saved me a **** load of trouble.
Thread Starter
|
Banned
Joined: Mar 2010
Posts: 5,403
Likes: 7
From: Southwest Florida
When I did my front turn signal relocation I managed to get to all the plugs with out completely removing the tank. Just unbolted everything thing and wiggled the tank back as far as it could go. Gotta be careful of the cross over line though. I read somewhere on here that they snap easy.
I'm no professional but it should be an easy job as long as you take your time.
I'm no professional but it should be an easy job as long as you take your time.
Thanks man. In the pdf instructions HERE, it says to remove the cover from underneath the main frame and disconnect the wiring harness from there.
2006-Later FXD:
See Figure 5. Remove cover under top
frame tube, then pull connector out from opening under
tube.
5. Disconnect 4-place headlamp connector [38] from main
5. Disconnect 4-place headlamp connector [38] from main
wire harness.
Is that what you did, or did you pull your wires out of the plug hole on the side of the frame? It sounds like, if you can get to it, pulling the connector from underneath might be the way to go.
Little hints from people like you, that have done it before, can save a lot of aggravation for people like me who haven't.
Thanks again for the help.
Thread Starter
|
Banned
Joined: Mar 2010
Posts: 5,403
Likes: 7
From: Southwest Florida
I installed a similar headlight. I cut the wires. Didn't go back under the tank for anything. All my connections are inside the bucket and are soldered/heat shrink wrapped. I know it's the the ideal way but my connections are sealed from the elements and are encased in the chrome bucket so I think it's damn fine the way it is and it saved me a **** load of trouble.
Maybe its because I always tried to use an electric soldering iron. Dunno. Never could get anything to stick right. Never.
A man's got to know his limitations. And soldering is near the top of my list.
Advanced
Joined: Mar 2010
Posts: 57
Likes: 0
From: Los Angeles
I have an 09 street bob so don't know how different it is but I had to pull the tank back then remove a shield under the front where the forks connect. then I pulled the wires out until I found the right ones. Turn signals were hard put it was pretty easy to find the head light wire.
Hard to jam them all in but read this morning that if you pull the wires from the seat section rather then jam back in they go a lot easier.
Hard to jam them all in but read this morning that if you pull the wires from the seat section rather then jam back in they go a lot easier.
Trending Topics
Elite HDF Member
Joined: May 2008
Posts: 4,579
Likes: 10
From: S.E. MO
Like stated you should be able to get the harness out without removing the tank. Tank gone makes it easier but it can be done with it on.
I would recommend looking at the Cobra ll light from Eastern Performance. It looks very similar and is only $99 shipped. I have had mine for over a year and still looks brand new. You would have to cut and splice it though.
I would recommend looking at the Cobra ll light from Eastern Performance. It looks very similar and is only $99 shipped. I have had mine for over a year and still looks brand new. You would have to cut and splice it though.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
6 Weirdest Harley-Davidsons Ever Sold to the Public
Verdad Gallardo
7 Times Harley-Davidson Chucked Tradition Out the Window
Verdad Gallardo
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
Cruiser
Joined: Jan 2008
Posts: 114
Likes: 0
From: Bellevue, WA
It's not that difficult with the tank still on. If you reach up under the tank near the front by the frame there is a plastic shield for the wiring harness, it has two tabs, one on each side that fit into the frame tubes, you can push it out and let it hang loose, remove the seat and between pushing and pulling on the wiring harness you should be able to get to the connector for the headlight. That's how I installed mine anyway. Also, if you prefer, removing the tank isn't that hard. Get yourself a piece of the appropriate size fuel line and two clamps. Find and remove the fuel pump fuse, run the starter for a few seconds to release all the pressure in the fuel line, remove the fuel line to the injectors using the quick disconnect fitting on the left side of the tank. Use two vise grips or equivalent to clamp off the crossover line, cut the line, remove the tank, drain the tank by removing the vise grips. All it's going to cost you is a buck or two for fuel line and clamps, I like the little springy ones. Also, in the box with that bullet headlight is a weird looking wrench for removing the inner bezel. Don't throw it out with the box, you'll need it to replace the bulb.