This is a brief description of the process I followed to install the seven inch headlight housing available through JCWhitney. Below is a list of the merchandise that I purchased to complete the headlight modification.
| |
Part |
Cost |
| A. |
7" Headlight Housing for Harley Davidson
(JCW Stock #06FF3928T) |
$42.99 |
| B. |
Chromed Mounting Bracket
(JCW Stock #06FF3950X) |
$8.49 |
| C. |
55-Watt H-4 Halogen Cycle Headlight
(JCW Stock #13FF9314A) |
$16.95 |
| D. |
One piece of steel, approximately 1 3/4" x 3" x 1/8" & welding cost |
$32.00 |
| E. |
Seven electrical butt connectors |
$0.49 |
| F. |
Two bolts, washers and locking nuts,
(same size as the factory mounting bolts and nuts, chrome plated is optional) |
$3.95 |
| G. |
One small can of outdoor chrome paint
(Chrome plating is another option) |
$3.65 |
| H. |
Extra electrical wiring may be needed |
$2.50 |
| |
APPROXIMATE TOTAL (without S&H): |
$112.00 |
MODIFICATION PROCEDURES
- Remove the factory headlight, then disconnect the wires to the headlight and remove all wiring from the headlight housing.
- Disconnect the brackets which hold the turn signals in place, (these brackets are part of the factory headlight housing), then remove the factory headlight housing.
- Take your 1 3/4" x 3" piece of steel and place it in the position where the factory headlight housing bracket mounted to the triple tree. Mark two points on the piece of steel where the mounting holes will be drilled and then drill them.
NOTE: Remember that once the mounting bracket is welded to the steel plate and mounted to the triple tree, there must be enough clearance for the headlight to be installed.
- The chromed mounting bracket must be cut from left to right, approximately 1 3/8" from the bottom of the bracket. The bottom of the bracket (with the two mounting holes), will no longer be needed.
- The upper portion of the mounting bracket must then be welded to the steel piece at a proper angle. An angle of approximately 60 degrees to the back or to the left, will allow the headlight housing adequate room to be adjusted up and down.
Once the desired angle is determined, have the mounting bracket welded to the steel piece. The bracket must be welded to the three inch end of the steel piece and at the point where the bracket was cut.
- Paint the modified mounting bracket with chrome paint or have it chrome plated. Once this has been completed, bolt the new mounting bracket to the triple tree.
- Cut off the end of the factory wiring harness that attached to the headlight. Route the new headlight wires through the back of the new headlight housing and use the butt connectors to attach the new wiring to the factory wires that were just cut.
NOTE: Additional wiring may be required when rerouting the factory wiring harness.
- After the headlight has been connected and the inner and outer headlight rings are installed, mount the headlight housing to the modified mounting bracket. Do not tighten completely, this will be completed once the headlight beam has been adjusted.
- Route the existing wiring harness underneath the gas tank. I did this to clean up the look of all those wires, this is not required.
NOTE: This routing may require longer wires to be used for the factory turn signals.
- Turn on the power and fully test the headlight and turn signals. Double check to make sure the headlight beam is adjusted properly.
- The turn signals may need to be tightened down. Without the factory bar that holds the turn signals in place, they may move. Electrical tape around around the front forks where the turn signals attach, may supply the extra grip
needed.
You have now completed the headlight modification, so RIDE, RIDE, RIDE.
Keep the shiny side up.
Jeff Selner
"Sel"
Thanks to Jeff Selner for this project!
