Question about 2004 Harley Davidson FLHT - FLHTI Electra Glide Standard

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How do i install a FLHR headlight nacelle onto my FLHT?

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Hi Martin, I'm sorry you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below: Good luck Harley Davidson Manuals Mark Workshop

Posted on May 14, 2015

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How to change headlight bulb on 02 road king police


I thought I would answer for ALL models so anyone else can read this and not have to post a new question which will take a considerable amount of time to answer again some other time and which therefore might not get answered as quickly as one would hope while in the need for an answer.



HEADLAMP (FLHR/C, FLHT/C/U)

HEADLAMP ASSEMBLY



To REMOVE:

First remove the Phillips screw at the bottom of the headlamp door chrome ring and remove the headlamp door.

On FLHT/C/U remove the four TORX screws to free the headlamp housing from the fairing.

On FLHR/C remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle.

Then if installed squeeze the two external tabs to remove the wire connector at the back of the headlamp bulb.

Next remove the headlamp housing assembly from the vehicle.



To RE-INSTALL:

First connect the wire connector at the backside of the headlamp bulb.

On FLHT/C/U align the holes in the headlamp housing with those in the fairing at the bottomof the headlamp door bracket and install the four TORX screws.

On FLHR/C align the holes in the headlamp housing with those in the headlamp nacelle at the bottom of the headlamp door bracket and install the eight Phillips screws.

Next fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door chrome ring into place and install the Phillips head screw at the bottom of the headlamp door and tighten it to 9-18 in-lbs which is (1.0-2.0 Nm).



To Replace the Headlight bulb:



First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. THEN remove the three Phillips head screws to free the retaining ring from the headlamp housing. THEN carefully remove the lens and bulb assembly and if installed squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb. THEN remove the lens and bulb assembly from the vehicle. THEN remove the rubber boot at the back of the lens and pushing down on the wire loops free their ends from the slots on the lens insert and swing the wire form out of the way.



HEADLAMP (FLHR/C, FLHT/C/U)

HEADLAMP ASSEMBLY



To Remove:

First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door.

On FLHT/C/U remove the four TORX screws to free the headlamp housing from the fairing.

On FLHR/C remove the eight Phillips head screws to free the headlamp housing from the headlamp nacelle.

THEN, if installed, squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb and remove the headlamp housing assembly from the vehicle.



To Re-Install:



First install the wire connector at the back of headlamp bulb.

On FLHT/C/U align the holes in the headlamp housing with those in the fairing at the bottom of the headlamp door bracket and install the four TORX screws.

On FLHR/C align the holes in the headlamp housing with the holes in the bottom of the headlamp nacelle headlamp door bracket and install the eight Phillips head screws. THEN fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and snap the headlamp door chrome ring into place and install Phillips head screw at the bottom of the headlamp door and tighten it to 9-18 in-lbs which is (1.0-2.0 Nm).



To replace the headlamp bulb:





First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. THEN remove the three Phillips head screws to free the retaining ring from the headlamp housing. THEN carefully remove the lens and bulb assembly and if installed squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb. THEN remove the lens and bulb assembly from the vehicle. THEN remove the rubber boot at the back of the lens and pushing down on the wire loops free their ends from the slots on the lens insert and swing the wire form out of the way.





To Align the headlight:



First verify that the bike has the correct front and rear tire inflation pressure and put the bike on a level surface in an a location with minimum light and point the front of the bike towards a screen or wall which is 25 feet (7.62 m) from where the patch of the front tire contacts the surface which would necessarily be directly below the front axle.

With a horizontal line drawn on the screen or wall precisely atthe same height above the floor as the centre of the headlamp and a person with roughly the same weight as that of the principal rider sitting on the seat of the bike to compress the suspension the same as t would be with the rider on the bike and with the bike in a fully upright position similar to the position it would be if being ridden straight ahead, (i.e. with both tires on the floor) and the front wheel pointed straight ahead at the screen or wall, turn the Ignition/Light Key Switch to IGNITION, set the Light Switch on the left handlebar to High beam and check the light beam against the screen or wall for the correct height alignment. The centre of the main light beam should be even with the horizontal line on the screen or wall and be pointed directly ahead so that there is an equal amount of light beam to the left and to the right of the centre mark on the screen or wall. (this would be the lateral alignment).

If the alignment is not correct it can be adjusted without removing the headlamp door chrome ring by using slots placed into the headlamp door through which a Phillips screw driver can be inserted (between the headlamp housing and the rubber gasket). By turning the vertical adjuster screw as necessary the headlamp can be adjusted vertically (up or down). By turning the horizontal adjuster screw as necessary the headlamp and be adjusted horizontally (left or right).



HEADLAMP (FLTR)

HEADLAMP ASSEMBLY

To Remove:

First remove the outer fairing and windshield and move it aside to a work area and squeeze the two external tabs to disconnect the headlamp harness connectors from the bulb contacts. THEN after wrapping some electrical tape around the blade of a screwdriver (to prevent damage to tabs of the transparent lens cover), from the inboard side of the outer fairing, release the top of the transparent lens cover from the slots in the fairing by gently

depressing the two tabs with the blade of the screwdriver. THEN depress the bottom two tabs and remove the lens cover from the fairing. THEN depress the mounting clips on the three hex adjuster studs and pull the headlamp assembly out from the front of the outer fairing.



To Install:

First align the hex adjuster studs with the plastic bosses on the inboard side of the outer fairing and push the headlamp assembly into position in the outer fairing until the mounting clips engage their bosses. THEN carefully snap the bottom tabs of the transparent lens cover into the bottom slots of the outer fairing and carefully snap the upper tabs of the lens cover into the upper slots of the outer fairing. THEN install the headlamp harness connectors onto the headlamp bulb contacts, install the outer fairing and windshield back onto the bike.



To Remove:

First remove the outer fairing and windshield. THEN move the outer fairing assembly to your chosen work area.

THEN squeeze the two external tabs to disconnect the headlamp harness connector from the headlamp bulb contacts, remove the rubber boot at the back of the headlamp bulb housing, rotate the plastic retainer in a counter-clockwise direction to remove from the headlamp bulb housing flange and remove the headlamp bulb.





To Re-Install:



First install the headlamp bulb into the headlamp bulb housing orient it so that the wider ear on the backplate is topside and then push the bottom of the backplate so that the tabs on the outboard side fit snugly into the slot of bulb housing. THEN place the plastic retainer over the bulb housing flange and rotate it in a clockwise direction until it is tight. THEN install the rubber boot over the retainer until it is flush with the base of the bulb socket, connect the headlamp harness connector to the headlamp bulb contacts install the outer fairing and windshield.



HEADLAMP ADJUSTMENT is same procedure as above except:



If the alignment is not correct it can be adjusted by locating the hex adjusters near the bottom edge of the inner fairing. Turning of the adjusters causes the double headlamp housing to pivot around its upper mount, so by using a 4.5 mm, 1/4 inch drive and a flexible driver the headlamp assembly can be adjusted horizontally by turning either the left or the right side adjuster. Both adjusters should be turned equally to adjust the headlamp vertically. Adjuster rotation moves the headlamp beam as follows: Left Only = Clockwise and Right Only = Counterclockwise and beam movement will be to the right.Left Only = Counterclockwise; Right Only = Clockwise and beam movement will be to the left. Left and Right Equally = Clockwise and beam movement will be upwards. Left and Right Equally = Counterclockwise and beam movement will be downwards.

Sep 03, 2014 | Motorcycles

1 Answer

Headlight handlebar


Remove headlight trim, remove ten screws holding haedlight assembly, remove nut under nacelle, pop the ignition decal up and remove the screws holding cover, remove the side bolts from windsheild bracket

Oct 21, 2013 | 2000 Harley Davidson FLHR-FLHRI Road king

1 Answer

Where does the nacelle switch accessory connect under the seat


Hi Anonymous, take a ride over to your local dealers service department I'm sure they will be happy to offer advice and assistance concerning your issue. Have a nice day

Oct 03, 2013 | 2011 Harley Davidson FLHR Road King

1 Answer

How to change 2003 road king headlamp nacelle


Hi Anonymous, for more information about your question please visit the websites below. Good luck and have nice day.
Steering Head Bearing Adjustment Harley Davidson Road King

Aug 30, 2012 | 2006 Harley Davidson FLHR Road king

1 Answer

Remove head lamp door on 2003 FLHRCI


HEADLAMP (FLHR/C, FLHT/C/U) HEADLAMP ASSEMBLY

To REMOVE:
First remove the Phillips screw at the bottom of the headlamp door chrome ring and remove the headlamp door. On FLHT/C/U remove the four TORX screws to free the headlamp housing from the fairing. On FLHR/C remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle. Then if installed squeeze the two external tabs to remove the wire connector at the back of the headlamp bulb. Next remove the headlamp housing assembly from the vehicle.

To RE-INSTALL:
First connect the wire connector at the backside of the headlamp bulb.On FLHT/C/U align the holes in the headlamp housing with those in the fairing at the bottom of the headlamp door bracket and install the four TORX screws. On FLHR/C align the holes in the headlamp housing with those in the headlamp nacelle at the bottom of the headlamp door bracket and install the eight Phillips screws.
Next fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door chrome ring into place and install the Phillips head screw at the bottom of the headlamp door and tighten it to 9-18 in-lbs which is(1.0-2.0 Nm).

To Replace the Headlight bulb:

The headlamp is not a sealed beam element but a replaceable Halogen gas filled Quartz bulb. It is filled with halogen gas under pressure and it is fragile so be careful not to break it as gas and glass splinters will fly out from it if it is broken. Also do not touch the bulb with your bare hands/fingers as this will etch the surface and cause early bulb failure. Also because use of a bulb that is not of the rated wattage could cause charging system problems always use only the correct wattage bulb.

First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. THEN remove the three Phillips head screws to free the retaining ring from the headlamp housing. THEN carefully remove the lens and bulb assembly and if installed squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb. THEN remove the lens and bulb assembly from the vehicle. THEN remove the rubber boot at the back of the lens and pushing down on the wire loops free their ends from the slots on the lens insert and swing the wire form out of the way.

HEADLAMP (FLHR/C, FLHT/C/U)
HEADLAMP ASSEMBLY

To Remove:
First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. On FLHT/C/U remove the four TORX screws to free the headlamp housing from the fairing. On FLHR/C remove the eight Phillips head screws to free the headlamp housing from the headlamp nacelle. THEN, if installed, squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb and remove the headlamp housing assembly from the vehicle.

To Re-Install:

First install the wire connector at the back of headlamp bulb.
On FLHT/C/U align the holes in the headlamp housing with those in the fairing at the bottom of the headlamp door bracket and install the four TORX screws.
On FLHR/C align the holes in the headlamp housing with the holes in the bottom of the headlamp nacelle headlamp door bracket and install the eight Phillips head screws. THEN fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and snap the headlamp door chrome ring into place and install Phillips head screw at the bottom of the headlamp door and tighten it to 9-18 in-lbs which is (1.0-2.0 Nm).

To replace the headlamp bulb:

The headlamp is not a sealed beam element but a replaceable Halogen gas filled Quartz bulb. It is filled with halogen gas under pressure and it is fragile so be careful not to break it as gas and glass splinters will fly out from it if it is broken. Also do not touch the bulb with your bare hands/fingers as this will etch the surface and cause early bulb failure. Also because use of a bulb that is not of the rated wattage could cause charging system problems always use only the correct wattage bulb.
First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. THEN remove the three Phillips head screws to free the retaining ring from the headlamp housing. THEN carefully remove the lens and bulb assembly and if installed squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb. THEN remove the lens and bulb assembly from the vehicle. THEN remove the rubber boot at the back of the lens and pushing down on the wire loops free their ends from the slots on the lens insert and swing the wire form out of the way.


To Align the headlight:

First verify that the bike has the correct front and rear tire inflation pressure and put the bike on a level surface in an a location with minimum light and point the front of the bike towards a screen or wall which is 25 feet (7.62 m) from where the patch of the front tire contacts the surface which would necessarily be directly below the front axle.
With a horizontal line drawn on the screen or wall precisely at the same height above the floor as the centre of the headlamp and a person with roughly the same weight as that of the principal rider sitting on the seat of the bike to compress the suspension the same as t would be with the rider on the bike and with the bike in a fully upright position similar to the position it would be if being ridden straight ahead, (i.e. with both tires on the floor) and the front wheel pointed straight ahead at the screen or wall, turn the Ignition/Light Key Switch to IGNITION, set the Light Switch on the left handlebar to High beam and check the light beam against the screen or wall for the correct height alignment. The centre of the main light beam should be even with the horizontal line on the screen or wall and be pointed directly ahead so that there is an equal amount of light beam to the left and to the right of the centre mark on the screen or wall. (this would be the lateral alignment).
If the alignment is not correct it can be adjusted without removing the headlamp door chrome ring by using slots placed into the headlamp door through which a Phillips screw driver can be inserted (between the headlamp housing and the rubber gasket). By turning the vertical adjuster screw as necessary the headlamp can be adjusted vertically (up or down). By turning the horizontal adjuster screw as necessary the headlamp and be adjusted horizontally (left or right).

HEADLAMP (FLTR)
HEADLAMP ASSEMBLY
To Remove:
First remove the outer fairing and windshield and move it aside to a work area and squeeze the two external tabs to disconnect the headlamp harness connectors from the bulb contacts. THEN after wrapping some electrical tape around the blade of a screwdriver (to prevent damage to tabs of the transparent lens cover), from the inboard side of the outer fairing, release the top of the transparent lens cover from the slots in the fairing by gently
depressing the two tabs with the blade of the screwdriver. THEN depress the bottom two tabs and remove the lens cover from the fairing. THEN depress the mounting clips on the three hex adjuster studs and pull the headlamp assembly out from the front of the outer fairing.

To Install:
First align the hex adjuster studs with the plastic bosses on the inboard side of the outer fairing and push the headlamp assembly into position in the outer fairing until the mounting clips engage their bosses. THEN carefully snap the bottom tabs of the transparent lens cover into the bottom slots of the outer fairing and carefully snap the upper tabs of the lens cover into the upper slots of the outer fairing. THEN install the headlamp harness connectors onto the headlamp bulb contacts, install the outer fairing and windshield back onto the bike.

HEADLAMP BULB REPLACEMENT
The headlamp is not a sealed beam element but a replaceable Halogen gas filled Quartz bulb. It is filled with halogen gas under pressure and it is fragile so be careful not to break it as gas and glass splinters will fly out from it if it is broken. Also do not touch the bulb with your bare hands/fingers as this will etch the surface and cause early bulb failure. Also because use of a bulb that is not of the rated wattage could cause charging system problems always use only the correct wattage bulb.

To Remove:
First remove the outer fairing and windshield. THEN move the outer fairing assembly to your chosen work area.
THEN squeeze the two external tabs to disconnect the headlamp harness connector from the headlamp bulb contacts, remove the rubber boot at the back of the headlamp bulb housing, rotate the plastic retainer in a counter-clockwise direction to remove from the headlamp bulb housing flange and remove the headlamp bulb.


To Re-Install:C
AUTION
First install the headlamp bulb into the headlamp bulb housing orient it so that the wider ear on the backplate is topside and then push the bottom of the backplate so that the tabs on the outboard side fit snugly into the slot of bulb housing. THEN place the plastic retainer over the bulb housing flange and rotate it in a clockwise direction until it is tight. THEN install the rubber boot over the retainer until it is flush with the base of the bulb socket, connect the headlamp harness connector to the headlamp bulb contacts install the outer fairing and windshield.

Jul 29, 2012 | 2003 Harley Davidson FLHRCI Road King...

1 Answer

Trying to wire front running lights on 07 road king


Right hand toggle switch on rear of headlight nacelle.

Jul 15, 2012 | 2007 Harley Davidson FLHR Road King

1 Answer

How to change handle bars


HANDLEBAR REMOVAL

1. Remove maxi-fuse.


REMOVAL



1. Remove left side saddlebag.




2. Gently pull side cover from frame downtubes (no tools



required).



3. Depress latches on maxi-fuse holder and then slide



cover rearward to disengage tongue from groove in fuse



block cover.



4. Pull maxi-fuse from maxi-fuse holder.

2. Place blanket or protective cover over front of fuel tank to

protect against scratches or other damage.



FLHR/C/S:

Remove the handlebar clamp

(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-

11, or NACELLE REMOVAL (FLHRS), steps 1-7.


WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2.31


WINDSHIELD REMOVAL
Standing at the front of the motorcycle,

use a finger to raise the wireform latch springs on


both sides of the windshield.


2. Gently pull on the top of the windshield until the upper


notches on the windshield brackets are free of the upper


grommets.


3. Carefully raise the windshield until the lower notches are


free of the lower grommets.


4. Remove windshield from motorcycle.


WINDSHIELD INSTALLATIONTo avoid scratching headlamp nacelle or auxiliary lamp


bracket, be sure that all four notches on the windshield


brackets are firmly seated on a rubber grommet.


1. Standing at the front of the motorcycle, carefully insert


the windshield brackets between the headlamp nacelle


and the auxiliary lamp bracket. Lower the windshield into


position until the lower notches on the windshield brackets


are seated on the lower grommets.


2. Gently push the top of the windshield toward the rear


until the upper notches fully engage the upper grommets.


3. Push down on the wireform latch springs, so that they


overhang the rubber grommets. If some adjustment is


necessary, loosen the retaining screws and rotate the


latch springs into the proper position.


NACELLE REMOVAL (FLHR/C)


1. Remove the windshield. See WINDSHIELD REMOVAL


on this page.


2. Remove the Phillips screw at the bottom of the headlamp


door (chrome ring). Remove the headlamp door.


3. Remove the eight Phillips screws to free the headlamp


housing from the headlamp nacelle.


FLTR:

Remove the instrument nacelle.

UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT

NACELLE, REMOVAL.

FLHT/C/U:

Remove the fairing cap.

Remove the outer fairing as follows:


a. Standing at the front of the vehicle, use a T27 TORX


drive head to remove the three outer fairing screws


(with flat washers) just below the windshield.


b. Moving to the inner fairing side, remove the two fairing


screws just above the wind deflectors on the left


and right side.


c. Turn the handlebar to the right and remove the outer


fairing screw reaching in below the left side of the


fairing cap. Turn the handlebar to the left and


remove the fairing screw below the right side of the


fairing cap.


d. Tilting the outer fairing toward the front, squeeze the


two external tabs to remove the wire connector at


the back of the headlamp assembly.


e. Lift the fairing (with headlamp assembly) off the


motorcycle.Since the outer fairing screws hold the windshield in


place, the windshield may fall to the floor if not removed.


UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING

CAP, REMOVAL. Remove the radio (or storage box).



4. Remove the left and right handlebar switch controls..

5. Remove upper handlebar clamp screws (with flat washers).

Remove upper handlebar clamps and handlebar.

HANDLEBAR INSTALLATION


Just reverse for install. This is all from the maunual and I hope it helps you.



Nov 25, 2010 | 2005 Harley Davidson FLHTC - FLHTCI...

1 Answer

Needing diagram of how to tighten handlebars on motorcycle


You have to remove the headlight, then the Nacelle ( passing lamps if you have them ) Under the lock ( which is removed with a small flat head screwdriver ( it's held in by 3 little push in tabs ) There are 2 phillips head screws( remove them ) then once you have the headlight out, there is a 5/16 nut holding the top chrome spine in place. Remove the nut lift the spline. then remove the nacelle one side at a time. Once you remove the nacelle the 1/4 allen bolts are right there to tighten. Make sure you tighten them evenly. Reverse steps to re-install back to normal.

Jul 30, 2009 | 2004 Harley Davidson FLHRS - FLHRSI Road...

1 Answer

Blowing fuses,battery too hot


Sounds like the voltage regulator is not working properly.

Jun 11, 2009 | 2000 Harley Davidson FLHR-FLHRI Road king

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