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)
Disassemble
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
Mark parts for location and orientation upon removal.
  1. Remove main fuse. See Maintenance and Lubrication → Fuses and Relays.
  2. See Figure 1. Remove trim ring hardware (1). Remove trim ring (2).
  3. Remove mounting ring (3).
  4. Disconnect headlamp connector (7) from bulb (5).
  5. LED: LED contains no service parts. Proceed to Assemble.
  6. Incandescent bulb:
    1. Remove boot (8) from back of headlamp lens (4).
    2. Remove wire retaining clip (6) from headlamp base.
    3. Remove bulb from headlamp assembly.
Assemble
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, make sure that connector contacts are clean for good electrical contact.
  1. Incandescent bulb:
    1. Install new bulb and assemble the headlamp components.
    2. Verify slots and tabs in headlamp and trim ring are aligned.
    3. Install boot on the headlamp lens assembly.
  2. Connect the headlamp connector.
  3. Install trim ring and hardware.
  4. Verify that ignition switch is in OFF position. Install main fuse.
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
  1. Check operation of all lamps.
  2. Align headlamp. See Maintenance and Lubrication → Headlamp Alignment.
1Trim ring hardware
2Trim ring
3Mounting ring
4Headlamp lens
5Bulb
6Wire retaining clip
7Headlamp connector
8Boot
9LED assembly
Figure 1. Headlamp Bulb: FLRT