-J05531 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-41183), 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.

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:

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 motorcycle 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.

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

NOTE

• 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.

• 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.

• Vehicles WITHOUT security siren: See the service manual to remove the main fuse.

-J05531 Many Harley-Davidson ® Parts & Accessories are made of plastics and metals which can be recycled.

Please dispose of materials responsibly.

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ALL Vehicles With Main Fuse:

is07133

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

1.

See the service manual to remove the main fuse.

ALL Vehicles With Main Circuit Breaker:

2

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.

2.

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 door 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.

1.

Chrome headlamp door

2.

Phillips-head screw

Figure 1. Remove Headlamp Door is07134

1

2

1.

Phillips-head screws

2.

No screw this location (2013- earlier)

Figure 2. Headlamp Housing Mount (FLHP) is07135

1

1

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1.

TORX-head screw (4)

Figure 3. Headlamp Housing Mount (FLHTP)

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INSTALLATION

The strobe lamp power supply is a source of high voltage.

Inadequate safety precautions can result in death or serious injury. (00097b)

• Do not perform any service while the system is operating.

• Wait 10 minutes after disconnecting the unit from the power source before servicing or troubleshooting on the power supply or system.

Proceed to Installation for the specific model.

Installation, 2013- Earlier FLHP Models

NOTE

The power supply mounts to a steel plate inside the nacelle.

• Remove the fir tree-style wire retainer from the steel plate in order to use the hole for mounting the power supply.

• The hole in the steel plate is slightly larger than the hole in the power supply mount.

• 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.

• Even if the overall fit appears less than perfect, the power supply becomes secure when the hardware is fully tightened.

3.

Install the screw up through the steel plate and power supply mount. Install the locknut (2), but do not fully tighten now.

4.

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 wiring 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.

is07137

3

2 is07136

1

1

2

3

4

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 treestyle 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.

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 supply as necessary.

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is07138

2

1

1.

Headlamp assembly

2.

Strobe power supply harness connector (2)

Figure 6. Install Strobe Harnesses to Headlamp (2013-

Earlier FLHP Models)

11. 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 harness connectors (2).

12. See Figure 2. Get the seven Phillips-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-lbs (1.0-2.0 Nm).

13. 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 Phillips-head screw (2) at the bottom. Tighten to 9-18 in-lbs (1.0-2.0 Nm).

Installation, 2014- Later FLHP Models

1.

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.

2.

Cut the high beam [C38HI) and low beam [C38LO] headlamp connectors from the vehicle harness.

3.

See Figure 15. Obtain the FLHP headlamp jumper harness

(16) from the kit.

4.

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.

Disassemble the strobing headlamp from the mounting ring (5) by removing the three retaining ring screws (12).

Retain the screws.

6.

See Figure 7. Remove two well nuts from the headlamp

nacelle (2) at the locations marked (1).

7.

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-lbs. (1.0-2.0 Nm).

is07825

2

3 4

5

1

4 5

1.

Remove well nut from nacelle (2)

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)

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1 is07826 is07827

3

4

1

5

2

4 5

3

2

1.

Power supply

2.

Screw slot (2)

3.

Bracket

4.

#10 screw (2)

5.

#10 flat washer (2)

Figure 8. Strobing Headlamp Power Supply (2014- Later

FLHP Models)

8.

See Figure 8. Mount the power supply (1) to the bracket

(3) as shown with 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-lbs. (2.3-3.4 Nm).

9.

Plug the power input harness into the power supply and route the wires out the rear of the nacelle.

10. 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-lbs. (2.3-3.4 Nm).

11. 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.

12. 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

13. See the service manual to install and crimp the ring terminal from the kit to the end of the black power supply ground wire.

1.

Power supply and bracket assembly

2.

Power supply bracket

3.

#10 screw (2)

4.

#10 flat washer (2)

5.

Headlamp mounting ring

Figure 9. Headlamp Power Supply Installation (2014- Later

FLHP Models)

14. Attach the black wire ring terminal to the left frame ground stud.

15. 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.

16. 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.

17. Get the sealed splice connector from the kit. See the service manual appendix to splice the red power supply wire to the two blue/black wire ends.

18. Plug the three way connector into the flasher.

19. Bring the strobing headlamp into position. Plug in the two strobe connectors.

20. Plug the headlamp harness into the headlamp bulb.

21. 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.

22. 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 necessary.

23. Fit the headlamp door spring into the slot at the top of the headlamp mounting ring.

24. Install the chrome headlamp door. Insert the Phillips-head screw at the bottom. Tighten to 9-18 in-lbs (1.0-2.0 Nm).

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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.

• The fir tree-style wire retainer must be removed from the steel plate in order to use the hole for mounting the power supply.

• The hole in the steel plate is slightly larger than the hole in the power supply mount.

• 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.

• Even if the overall fit appears less than perfect, the power supply becomes secure when the hardware is fully tightened.

is07139

1 2 is07141

1

2

4

3

1.

Steel plate

2.

Locknut

3.

Power supply

4.

Strobe harness (2)

Figure 11. Mount the Power Supply (2013- Earlier FLHTP

Models)

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) ring 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.

8.

See Figure 13. Route the red power supply wire (4) upward

and toward the right side of the plastic radio mounting box

(1).

is07140

3

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 the steel plate.

4.

Install the screw from the opposite side (under the fairing cap), through the steel plate (1) and power supply (3) mount. Install the locknut (2), but do not fully tighten now.

5.

Route the two strobe power supply harnesses (4), the red power wire and the black ground wire away from the power supply and free of other wiring in the fairing.

3

2

4

1

1.

Power supply

2.

Locknut

3.

Black ground wire

4.

Ring terminal

Figure 12. Install Ground Wire Ring Terminal (2013- Earlier

FLHTP Models)

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1

2 3

5

18. 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 Phillips-head screw (2) at the bottom. Tighten the screw to 9-18 in-lbs (1.0-2.0 Nm).

Installation, 2014- Later FLHTP Models

1.

Remove the windshield, outer fairing, seat and fuel tank per the service manual.

2.

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-lbs (2.8-4.0 Nm).

5

4

6 is07828

1

2

1.

Radio mounting box

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-

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.

9.

Locate the pursuit flasher (2) and the three-way connector

[69B] (3) plugged into the flasher. Unplug the connector.

10. Select the gray/black wire (5) in the connector. Cut the wire about 4-5 in (100-125 mm) from the connector.

11. 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).

12. Plug the three-way connector into the flasher. Carefully tuck the wiring in and around the surrounding wiring.

13. 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.

14. Use cable straps to secure the power supply as necessary.

15. See the service manual to install the outer fairing and windshield.

16. 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 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 harness connectors.

17. 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).

4

3

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)

3.

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 to left or right fork stops.

4.

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

5.

See the service manual to install and crimp the ring terminal from the kit to the end of the black power supply ground wire.

6.

Attach the black wire ring terminal to the left frame ground stud.

7.

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.

8.

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.

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9.

Get the sealed splice connector from the kit. See the service manual appendix to splice the red power supply wire to the two blue/black wire ends.

10. Plug the three way connector into the flasher.

11. See Figure 15. Obtain the FLHTP headlamp jumper har-

ness (17) from the kit. Plug the harness into the vehicle headlamp connector [C38B].

12. Using cable straps (not supplied) to secure all power supply wiring. Make sure that the wires are not pinched and will not chafe.

13. Install the outer fairing and windshield per the service manual.

14. Get the strobing headlamp assembly (1) from the kit.

Reach in through the headlamp opening and retrieve the headlamp connector and the two strobe harnesses coming from the power supply.

15. Plug the two strobe connectors into the strobe bulbs. Plug the headlamp harness into the headlamp bulb.

16. Install the headlamp assembly to the opening in the fairing with the four screws removed earlier. Tighten the screws to 22-32 in-lbs (2.5-3.6 Nm).

17. 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.

Secure the headlamp door with the OE screw. Tighten the screw to 9-18 in-lbs (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.

2.

Test the headlamp and strobe lamps for proper operation.

If installed properly, the strobes will turn on and flash with the front emergency lamps.

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.

See the service manual to install the fuel tank if removed.

Install the seat.

4.

Align the headlamp per the service manual.

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SERVICE PARTS

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12

1

3

17

4

11

2

9

15

13

5

14

6

16

10

18

4

15

9

7

8

Figure 15. Service Parts, Emergency Headlamp and Strobe Kit

Table 1. Service Parts

12

13

14

15

16

17

18

7

8

9

10

11

4

5

6

Item

1

Description (Quantity)

Headlamp assembly (includes Item 2)

2

3

• Boot, headlamp bulb

Bulb, headlamp, H4, Performance

Bulb, strobe (2) (with separate connector)

Mounting ring assembly, strobing headlamp

Power supply

Ring terminal, #16-22 AWG, for 1/4 in (6.4 mm) diameter stud

Sealed splice connector (blue)

Screw, TORX button head, #10-24 x 1/2 in (12.7 mm) long

Lock nut, #10-24, with nylon insert

Retaining ring, headlamp

Screw, retaining ring (3)

Washer (7)

Bracket, power supply

Flat washer, #10 (4)

Headlamp jumper harness, FLHP models

Headlamp jumper harness, FLHTP models

Power input harness

Part Number

67636-02

Not sold separately

67074-02

68692-02

Not sold separately

90051-02

9858

70586-93

2478

7624

67726-08

67721-48

6717

Not sold separately

6716

Not sold separately

Not sold separately

Not sold separately

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