Removal
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
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)
  1. Remove main fuse. See Service Procedures → Fuses.
  2. For Model XL1200NS: See Service Procedures → Headlamp Alignment.
    1. Remove headlamp visor.
  3. See Figure 2. Loosen the trim ring screw (4). Remove the trim ring.
  4. Support the lens and reflector.
  5. See Figure 1. While compressing the release tabs (1) on the connector, pull the connector off the bulb spade terminals.
  6. Pull the rubber boot (2) back.
  7. Press the loop (3) on the wire retaining clip (4) down and to one side to disengage the free end of the clip from the metal catch. Rotate the clip up. Remove the bulb from the lens and reflector.
1Release tab
2Rubber boot
3Loop
4Retaining clip
Figure 1. Headlamp
Installation
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
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)
1. Align bulb tabs with slots in the reflector. Install the bulb.
2. See Figure 1. Rotate the retaining clip down against the bulb flange. Press the wire loop down and in until the free end of the clip engages the metal catch.
3. See Figure 2. Match the rubber boot TOP arrow to the reflector arrow (1). Fit the rubber boot over the spade terminals of the bulb. Press the air out of the boot to seal over the lens and the reflector assembly.
4. Install the connector.
5. Verify that the adapter ring (2) is in place with the two tabs of the ring in the two bulges in the headlamp shell.
6. Match the single tab on the reflector to the notch (3) on the inside of the adapter ring.
7. For Model XL1200C: Install rubber finger gasket (5).
8. Fit the trim ring and rotate the ring clockwise to lock the ring on the lens and reflector.
9. All except XL1200C: Install screw (4) and nut. For Model XL1200C: Install screw (4).
10. Tighten screw.
Torque: 1.0–1.6 N·m (9–14 in-lbs)
11. Install main fuse. See Service Procedures → Fuses.
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)
12. Test headlamp operation.
13. Align headlamp. See Service Procedures → Headlamp Alignment.
14. For Model XL1200NS: Install headlamp visor. See Service Procedures → Headlamp Alignment.
1Arrows
2Adapter ring
3Notch
4Screw
5Finger gasket
6All except XL1200C
7XL1200C
Figure 2. Headlamp Assembly