Harley Davidson 2018 softail models. Service manual — page 26
1
Screw
2
Bezel
3
Isolator (2)
4
Nacelle
5
Screw (3)
6
Retainer
7
Headlamp
8
Gasket
9
Mounting ring
10
Ground strap
11
Connector
12
Screw
Figure 1. Nacelle Mounted Headlamp
Remove
1. See Figure 1. Remove screw (3).
2. Remove headlamp (1).
3. Disconnect connector (2).
Install
1. See Figure 1. Connect connector (2).
2. Install headlamp (1).
3. Install screw (3). Tighten.
Torque: 13.5-17.6 N·m (10-13 ft-lbs) Headlamp
(Oblong) mounting screw
1
Headlamp
2
Connector
3
Screw
Figure 1. Oblong Headlamp
See Remove and Install: Horizontalfor bulb replacement.
1. Remove main fuse. See Main Fuse.
2. Remove associated parts:
Round headlamp: Remove fuel tank. See Prepare.
Model with windshield: Remove windshield. See Remove.
Model with nacelle: Remove nacelle. See Prepare.
Model with fairing: Remove fairing. See Remove and Install.
Remove
1. Disconnect headlamp connector. See Prepare.
2. See Figure 1. Remove locknut (6) and flat washer (5).
3. Remove screw (2) and flat washer (3).
4. Remove headlamp (1).
1
5 3/4 or 7-inch headlamp
2
Screw
3
Washer
4
Mounting bracket
5
Washer
6
Locknut
Figure 1. Round Headlamp (Typical)
Install
1. See Figure 1. Install headlamp (1).
2. Install screw (2) and flat washer (3).
3. Install flat washer (5) and locknut (6). Tighten. Torque:
36.6-43.3 N·m (27-32 ft-lbs) Headlamp, round, locknut
4. Connect headlamp connector. See Prepare.
Remove
1. Remove nacelle. See Prepare.
2. Remove headlamp. See Bulb Replacement in this
section.
3. See Figure 1. Remove screw and washer (2).
4. Remove mounting ring (1).
1
Mounting Ring
2
Screw and washer (2)
Figure 1. Headlamp Mounting Ring
Install
1. See Figure 1. Install mounting ring (1).
2. Install screw and washer (2). Tighten.
Torque: 21.6-27.1 N·m (16-20 ft-lbs) Headlamp
mounting ring screw
3. Install headlamp. See Bulb Replacement in this section.
4. Install nacelle. See Prepare.
Remove
1. Remove clutch cable from wireform.
2. See Figure 1. Remove mounting bracket.
a. Remove screws (1).
b. Remove headlamp (2).
c. Disconnect connector (4).
d. Remove screw and wireform (3).
3. See Figure 2. Disassemble mounting bracket.
a. Remove screws (5) and spacers (4).
b. Discard isolators (3).
1
Screw (2)
2
Headlamp
3
Wireform and screw
4
Connector
Figure 1. Headlamp
1
Mounting bracket
2
Mounting clevis
3
Isolator (2)
4
Spacer (4)
5
Screw (4)
Figure 2. Oblong Headlamp Mounting Bracket
Install
1. See Figure 2. Assemble mounting bracket.
a. Assemble bracket (1), new isolators (3) and clevis
(2).
b. Install spacers (4) and screws (5). Tighten. Torque:
3.7-4.8 N·m (3-4 ft-lbs) Oblong headlamp isolator
screw
2. See Figure 1. Install mounting bracket.
a. Install wireform and screw (3). Tighten.
Torque: 13.5-16.2 N·m (10-12 ft-lbs) Oblong
headlamp wireform screw
b. Connect connector (3).
c. Install headlamp (2).
d. Install screws (1). Tighten.
Torque: 21.6-27.1 N·m (16-20 ft-lbs) Headlamp,
upper triple clamp mounted, screw
3. Install clutch cable into wireform.
Remove
1. See Figure 1. Remove screws (1).
2. Remove nacelle (2).
3. See Figure 2. Remove screws (1).
4. Disconnect connector (3).
5. Remove headlamp (2).
1
Screw (2)
2
Nacelle
Figure 1. Headlamp Nacelle
1
Screw (3)
2
Headlamp
3
Connector
Figure 2. Headlamp
Install
1. See Figure 2. Install headlamp (2).
2. Connect connector (3).
3. Install screws (1). Tighten.
Torque: 15-19 N·m (11-14 ft-lbs) Headlamp, upper
triple clamp mounted, screw
4. See Figure 1. Install nacelle (2).
5. Install screws (1). Tighten.
Torque: 21.6-27.1 N·m (16-20 ft-lbs) Headlamp
nacelle, screw
WARNING
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. (00030b)
Prepare
1. Check tire pressure.
2. Adjust rear shock preload for rider and intended load.
3. Fill fuel tank or add an equal amount of ballast.
Check Alignment
1. See Figure 1. Park the motorcycle on a line (1)
perpendicular to the wall.
2. Set vehicle distance from wall to front axle. Distance:
7.6 m (25 ft)
3. Draw a vertical centerline (2) on the wall aligned with
line (1).
4.
NOTE
The upper lens half of LED is the low beam.
With the motorcycle loaded, point the front wheel
straight forward at wall.
a. All except FXFB/S: Measure the distance (4) from
the floor to the center of headlamp.
b. FXFB/S: Measure the distance (4) from the floor to
the center of low beam.
5. Draw a horizontal line (5) through vertical line (2) using
the same height measurement as low beam bulb
centerline (4).
6. Align the top of the hot spot to horizontal line (5) with
headlamp set to low beam.
7. Adjust headlamp, if necessary.
1
Perpendicular line
2
Vertical line
3
7.6 m (25 ft)
4
Low beam bulb centerline
5
Horizontal line
Figure 1. LED Headlamp Alignment
Round
1. All except FLSB and FLSL: See Figure 1. Loosen
horizontal adjustment screw (2). Adjust headlamp
horizontally to direct light beam straight ahead.
2. Tighten horizontal adjustment screw:
a. FLDE, FLHC:
Torque: 25-40.6 N·m (18-30 ft-lbs) Headlamp
FLDE, FLHC, FLSB horizontal adjustment screw
b. FXBB, FXLR:
Torque: 29.8-37.9 N·m (22-28 ft-lbs) Headlamp
FXBB, FXLR horizontal adjustment screw
3. Loosen vertical adjustment screw (1). Adjust headlamp
vertically until beam centers on horizontal line.
4. Tighten vertical adjustment screw (1):
Torque: 36.6-43.3 N·m (27-32 ft-lbs) Headlamp FLDE,
FLHC, FLSL, FXBB, FXLR, FLSB vertical adjustment
screw
1
Vertical adjusting bolt
2
Horizontal adjusting bolt
Figure 1. Headlamp Adjustment
FXBR/S and FXFB/S
1. See Figure 2 and Figure 3. Loosen vertical adjustment
screw (3). Adjust headlamp vertically until beam centers
on horizontal line.
2. Tighten vertical adjustment screw (3):
a. FXBR/S See Figure 2.
Torque: 13.5-17.6 N·m (10-13 ft-lbs) Headlamp
FXBR/S vertical adjustment screw
b. FXFB/S See Figure 3.
Torque: 14.9-19 N·m (11-14 ft-lbs) Headlamp
FXFB/S vertical adjustment screw
1
FXBR/S Headlamp
2
Mounting bracket
3
Screw
Figure 2. Headlamp Adjustment
1
FXFB/S Headlamp
2
Mounting bracket
3
Screw (2)
Figure 3. Headlamp Adjustment
FLFB/S
1. See Figure 4. Rotate horizontal adjustment screw (1).
Adjust headlamp horizontally to direct light beam
straight ahead.
2. Rotate vertical adjustment screw (2). Adjust headlamp
vertically until beam centers on horizontal line.
1
Horizontal adjustment screw
2
Vertical adjustment screw
Figure 4. Headlamp Adjustment
1. Install associated parts:
Round headlamp: Install fuel tank. See Prepare.
Model with windshield: Install windshield. See Remove.
Model with nacelle: Install nacelle. See Prepare.
Model with fairing: Install fairing. See Remove and Install.
2. Install main fuse. See Main Fuse.
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)
3. Test headlamp for proper operation.
4. Align headlamp. See Align in this section.
Prepare
1. Remove main fuse. See Main Fuse.
2. Remove fuel tank. See Prepare.
Remove
1. Disconnect right and left turn signal connectors. See
Prepare.
2. See Figure 1. Remove screws (1).
3. Remove light bar.
1
Screw (2)
Figure 1. Front Light Bar
Disassemble
1. See Figure 2. Discard cable strap (3).
2. Remove screws (2) and bracket (1).
3. Remove auxiliary lamp housings. See Bulb
Replacement.
4. See Figure 3. Remove screws (1) and clamps (2).
5. Remove left and right turn signals (3, 4).
1
Bracket
2
Screw (2)
3
Cable strap
Figure 2. Light Bar Bracket
1
Screw (2)
2
Clamp (2)
3
Left turn signal
4
Right turn signal
Figure 3. Light Bar Disassembly
Assemble
1. See Figure 3. Install left and right turn signals (3, 4).
2. Install screws (1) and clamps (2). Tighten.
Torque: 0.67-1.1 N·m (6-10 in-lbs) Front light bar,
clamp screw
3. Install auxiliary lamp housings. See Bulb Replacement.
4. See Figure 2. Install screws (2) and bracket (1).
Tighten.
Torque: 21.7-27.1 N·m (16-20 ft-lbs) Front light bar,
bracket screw
5. Install new cable strap (3).
Install
1. Install light bar.
2. See Figure 1. Install screws (1). Tighten.
Torque: 27.1-33.9 N·m (20-25 ft-lbs) Front light bar
mounting screw
3. Connect right and left turn signal connectors. See
Prepare.
Remove
1. Disconnect right and left turn signal connectors. See
Prepare.
2. See Figure 1. Remove screws (1).
3. Remove light bar.
1
Screw (2)
Figure 1. Lightbar Assembly
Disassemble
1. Remove LED turn signals. See Bulb Replacement.
2. Disconnect and remove harness from light bar.
3. Remove auxiliary lamp housings. See Bulb
Replacement.
Assemble
1. Install auxiliary lamp housings. See Bulb Replacement.
2. Install and connect harness to light bar. See electrical
diagnostic manual.
3. Install LED turn signals. See Bulb Replacement.
Install
1. Install light bar.
2. See Figure 1. Install screws (1). Tighten.
Torque: 27.1-33.9 N·m (20-25 ft-lbs) Front light bar
mounting screw
3. Connect right and left turn signal connectors. See
Prepare.
Complete
1. Install fuel tank. See Prepare.
2. Install main fuse. See Main Fuse.
Bulb
Remove
1. See Figure 1. Remove screw (1) and nut (2).
2. Remove bezel (3).
3. Remove LED lamp (4).
4. Disconnect connector (5).
Install
1. See Figure 1. Connect connector (5).
2. Install LED lamp (4) in alignment ring (6).
3. Install bezel (3).
4. Install screw (1) and nut (2). Tighten.
Torque: 0.67-1.12 N·m (6-10 in-lbs) Auxiliary lamp
bezel nut
1
Screw
2
Nut
3
Bezel
4
LED Lamp
5
Connector
6
Alignment ring
Figure 1. LED Auxiliary Lamp
1. Remove main fuse. See Main Fuse.
2. Remove bulb. See Bulb Replacement.
Remove
1. See Figure 1. Disconnect pins (4) from connector (2).
2. Remove nut (3).
3. Remove housing (1).
1
Housing
2
Connector
3
Nut
4
Pin (2)
Figure 1. Auxiliary Lamp Housing with Incandescent Signal
Install
1. See Figure 1. Install housing (1).
2. Position housing. Install nut (3) and tighten.
Torque: 20.3-24.4 N·m (15-18 ft-lbs) Auxiliary lamp nut
3. Connect pins (4) to connector (2). See electrical
diagnostic manual.
4. Align auxiliary lamps. See Align in this section.
Remove
1. See Figure 1. Disconnect pins (3) from connector (2).
2. Remove nut (6), lockwasher (5), and swivel clamp (4).
3. Remove housing (1).
1
Housing
2
Connector
3
Pin (2)
4
Clamp
5
Lockwasher
6
Nut
Figure 1. Auxiliary Lamp Housing with LED Signal
Install
1. See Figure 1. Install housing (1).
2. Position housing. Install swivel clamp (4), lockwasher
(5), and nut (3). Tighten.
Torque: 20.3-24.4 N·m (15-18 ft-lbs) Auxiliary lamp nut
3. Connect pins (3) to connector (2). See electrical
diagnostic manual.
4. Align auxiliary lamps. See Align in this section.
Check Alignment
1. Place vehicle facing target wall as described in Align
section of Headlamp. See Bulb Replacement:
Standard Round.
2. Check headlamp alignment. Adjust if necessary.
Auxiliary Lamp Adjustment
NOTE
Have a person weighing roughly the same as the principal rider sit on the motorcycle.
1.
With the vehicle upright and a rider seated on the
motorcycle, measure the distance from the floor to the
centerline of each auxiliary lamps.
2.
See Figure 1. Mark the center of the headlamp high
beam by making a vertical line through the horizontal
line already drawn on the wall. Properly adjusted, the
beam should project an equal area of light to the left and
right of the vertical centerline (1).
3.
Measure the horizontal distance from the headlamp
vertical centerline to the vertical centerline of each
auxiliary lamp.
4.
Mark the auxiliary lamp horizontal and vertical centerline
(2, 3) on the wall.
5.
FLDE Adjust auxiliary lamps.
a. See Figure 2. Using flare nut socket loosen nut (6).
b. Adjust auxiliary lamp.
c. Tighten nut (6).
Torque: 20.3-24.4 N·m (15-18 ft-lbs) Auxiliary lamp
nut (FLDE)
6.
NOTE
Minimize auxiliary lamp movement while tightening
to maintain alignment.
FLHC Adjust auxiliary lamps.
a. Remove bulb. See Auxiliary Lamps in this section.
b. See Figure 3. Loosen nut (3).
c. Adjust housing (1).
d. While holding auxiliary lamp housing (1) steady,
tighten nut (3)
Torque: 25.7-31.1 N·m (19-23 ft-lbs) Auxiliary lamp
nut (FLHC)
e. Install bulb. See Auxiliary Lamps in this section.
7.
Verify auxiliary lamp alignment.
1
Headlamp centerline
2
Left auxiliary lamp centerline
3
Right auxiliary lamp centerline
4
Left auxiliary lamp beam area
5
Right auxiliary lamp beam area
6
Headlamp low beam area
Figure 1. Headlamp Pattern: LED Type with Auxiliary Lamps
1
Housing
2
Connector
3
Pin (2)
4
Clamp
5
Lockwasher
6
Nut
Figure 2. Auxiliary Lamp Housing with LED Signal
1
Housing
2
Connector
3
Nut
4
Pin (2)
Figure 3. Auxiliary Lamp Housing with Incandescent Signal
1. Install bulb. See Bulb Replacement.
2. Install main fuse. See Main Fuse.
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)
3. Check operation of all lamps.
Incandescent
1. See Figure 1. Replace bulb.
a.
Remove lens.
b.
Replace bulb.
c.
Install lens.
Figure 1. Remove Lens
LED
Remove
1. See Figure 2. Remove screws (1).
1
Screw (2)
Figure 2. Lightbar Assembly
2. Support lightbar assembly.
3. See Figure 3. Remove screws (1).
4. Remove cover (2).
1
Screw (4)
2
Cover
Figure 3. Lightbar Cover
5. See Figure 4. Remove screw (1).
6. Remove LED signal (3 or 4).
7. Disconnect connector (2).
1
Screw (2)
2
Connector
3
LED, left
4
LED, right
Figure 4. Lightbar LED Signal
Install
1. See Figure 4. Connect connector (2).
2. Install LED signal (3 or 4).
3. Install screw (1). Tighten.
Torque: 2.25-3.2 N·m (20-28 in-lbs) LED signal
screw
4. See Figure 3. Install cover (2).
5. Install screws (1). Tighten.
Torque: 2.25-3.2 N·m (20-28 in-lbs) Lightbar, front,
cover screw
6. Install lightbar assembly.
7. See Figure 2. Install screws (1). Tighten.
Torque: 27.1-33.9 N·m (20-25 ft-lbs) Lightbar, front,
screw
Prepare
1. Remove main fuse. See Main Fuse.
2. Remove fuel tank. See Prepare.
Remove
1. See Figure 1. Remove front turn signals.
a. Loosen set screw (7).
b. Loosen locknut (3) and remove ball stud (6) from
turn signal.
2. Remove hand control module from handlebar.
a. Left hand control module: See Prepare.
b. Right hand control module: See Prepare.
3. Disconnect left or right turn signal connector. See
Prepare.
4.
NOTE
Verify that there is enough scrap wire to work both
ends of handlebar when wiring is routed through
handlebar.
Route turn signal wires through handlebar.
a. Attach scrap wire to turn signal connector.
b. Pull turn signal wiring through handlebar.
c. Disconnect scrap wire from old turn signal
connector. Attach scrap wire to new turn signal
wiring.
1
Mirror
2
Turn signal bracket
3
Locknut
4
Acorn nut
5
Lockwasher
6
Ball stud
7
Set screw
Figure 1. Front Turn Signals
Install
1.
NOTE
Verify that there is enough scrap wire to work both
ends of handlebar when wiring is routed through
handlebar.
Route turn signal wires through handlebar.
a. Disconnect scrap wire from old turn signal
connector. Attach scrap wire to new turn signal
wiring.
b. Pull new turn signal wiring through handlebar.
c. Remove scrap wire.
2.
Install hand control module to handlebar.
a. Left hand control module: See Prepare.
b. Right hand control module: See Prepare.
3.
Connect left or right turn signal connector. See Prepare.
4.
See Figure 1. Install front turn signal.
NOTE
When installing right side turn signal assembly, do
not cover brake lever pivot pin.
a. Install ball stud (6) to turn signal and tighten locknut
(3).
Torque: 5.6-7.9 N·m (50-70 in-lbs) Handlebar-
mounted turn signal, ball stud locknut
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