WARNING

Handle bulb carefully and wear eye protection. Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062b)

NOTICE

When replacement is required, use only the specified sealed beam unit or bulb, available from a Harley-Davidson dealer. An improper wattage sealed beam or bulb, can cause charging system problems. (00209a)

If a headlamp bulb filament burns out, the bulb must be discarded and a new bulb installed. Refer to Specifications → Specifications → Bulb Chart for bulbs.

Bulb Removal

WARNING

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

NOTE

Make note of components during disassembly to aid in correct assembly.

1.	Remove main fuse. See Maintenance and Lubrication → Fuses and Relays.
2.	See Figure 1. Remove mounting screw at bottom of trim ring. Remove trim ring.
3.	Remove retaining screws and retaining ring.
4.	Remove headlamp connector from lens assembly.
5.	Remove lens assembly and remove rubber boot.
6.	See Figure 2. Release wire retaining clip (1) from retainer (2). NOTE It may be necessary to loosen wire clip retainer screw one-half to one-full turn to release wire clip.
	WARNING Handle bulb carefully and wear eye protection. Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062b)
7.	Remove and discard bulb.

Installation

NOTICE

Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Handle the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210b)

NOTE

When installing a new bulb, be sure connector contacts are clean for good electrical contact.

1.	See Figure 1. Align the tab on the bulb with the notch in the headlamp housing.
2.	Install new bulb and assemble the headlamp components. NOTE Verify that reflector cone is still centered under decorative logo. If it is not, loosen wire clip retainer screw and repeat step until the proper results are achieved.
3.	Install rubber boot at back of lens housing.
4.	Connect the headlamp connector.
5.	Install headlamp connector on headlamp bulb.
6.	Install headlamp assembly and tighten screws to: 1–2 N·m (9–18 in-lbs).
7.	Fit the trim ring spring into slot at top of headlamp housing and secure the trim ring with screw. Tighten to 2.5–3.6 N·m (22–32 in-lbs).

1	Housing
2	Mounting ring
3	Adjusting screw
4	Rubber boot
5	Bulb
6	Headlamp lens
7	Retaining ring
8	Trim ring spring
9	Trim ring
10	Mounting screw
11	Retaining screw
12	Mounting screw

Figure 1. Replace Headlamp: Single Headlight

1	Wire retaining clip
2	Retainer

Figure 2. Wire Retaining Clip