Harley-Davidson bfr540 Manual Do Utilizador

-J01588

REV. 3-2-00

This kit is designed for installation on 1994 and later FLHR
(Road King) Model Motorcycles.

2

Cable strap

10065

2

Screw, machine panhead

2589

3

Connector, butt

70585-93

1.

Disconnect battery cables, negative cable first.

2.

Following instructions in applicable Service Manual,

remove the windshield.

3.

Remove the phillips screw at the bottom of the of the

headlamp door (chrome ring). Remove the headlamp
door.

4.

Remove the seven Phillips screws to free the headlamp

housing from the headlamp nacelle.

5.

Squeeze the two external tabs (if present) to remove

the wire connector at the back of the headlamp bulb.
Remove the headlamp housing assembly and set aside.

6.

See Figure 1. Reaching inside the headlamp nacelle,

remove the speed nut to release the chrome strip at the
top of the nacelle. 

7.

Remove the wire form clip holding the halves of the

nacelle together at the bottom.

8.

Carefully pry off the fork lock plate at the rear of the

handlebar clamp shroud. Remove two Phillips screws
beneath the lock plate.

9.

Loosen the Phillips screw from the tab at the front of the

handlebar clamp shroud (but do not remove).

10. Loosen the two acorn nuts from the left and right side

fork studs.

11. Raise the handlebar clamp shroud slightly, and while

separating the halves of the headlamp nacelle, remove
the shroud from the vehicle. 

12. Carefully align the template over the handlebar shroud

cover and tape into place.

13. Exercising caution to avoid scratching, secure the

shroud in a vise or use other suitable means.

14. Use a center punch and carefully punch the drill hole

locations. See Figure 2. Make sure to punch indentation
deep enough to keep the bit from skating during the
drilling procedure.

15. Drill one 1/4” hole and two 5/32” holes as indicated on

the Drill Template (attached).

1

1

1

®

i02098.eps