DIY Network

Install Headlights, Handlebar Levers and Windshield From "Classic Rides" episode DCLR-109

In this second segment host Kevin Tetz is joined by expert mechanic Bill "Dunk" Dunkelberger to install the headlights, handlebar levers and the new windshield on the '65 Harley-Davidson Electra Glide project bike.

Installing the Headlight and Handlebar Levers

• The first half of the headlight housing (figure A) goes into place, and then the right running light and turn signal follow. Dunk leaves the bracket mounting loose until the wiring and headlight are installed.

• The other half of the headlight housing slips into place, and the left running light and turn signal is mounted (figure B).

Figure A

Figure B

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	Figure C
	Figure D
	Figure E
	Figure F

• Now it's time to work with the wiring. Wrap the wires with corrugated tubing (figure C), and then run them around the forks and to the electrical panel.

• After checking the wiring diagram, hook up the wires for the running lights and turn signals.

  Note: Know that each motorcycle has its own set of quirks and individual characteristics. These instructions may not totally apply to your restoration project. Always be sure to refer to experts, manuals and several other qualified sources before undertaking a complete restoration project.

• Then install the headlight, plugging the connection into the bulb, and secure it with the mounting screws.

• The headlight ring goes on (figure D) and is secured into place.

• Go back and tighten the running light and turn signal brackets.

• The handlebar cover goes on. Slip a cable guide over the right-hand cable and secure that to the headlight housing. The cable end slips into the lever, and the lever is installed onto the handlebar fitting.

• The locking pin goes in through the fitting and lever (figure E) -- and is secured in place with a clip.

• Do the same on the other side.

• Finally, the new reproduction windshield goes on by slipping it over the headlight housing and bolting into place (figure F).

In the next segment the saddlebags, speedometer are installed, along with the finishing touches.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Knoxville Harley-Davidson Information
Knoxville Harley-Davidson/Buell
Website: www.HarleyofKnoxville.com

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Reproduction Windshields and Other Parts
National Cycle, Inc.
Website: www.nationalcycle.com

Specialty Tools and Kits
Cruz Tools
Website: www.cruztools.com

Motorcycle Covers
Covercraft Quality Softgoods
Covercraft Industries, Inc.
Website: www.covercraft.com

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com