Removal
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)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Remove main fuse. See Maintenance and Lubrication → Fuses and Relays.
  2. See Figure 1. Remove screw and headlamp trim ring. Refer to Table 1.
  3. Hold headlamp reflector/lens and compress release tabs on sides of bulb connector to pull connector from spade terminals.
  4. Remove headlamp reflector/lens and metal adapter ring.
  5. Pull rubber boot from back of reflector/lens.
  6. Press ends of retaining clip to unhook from notched retaining tabs and pivot retaining clip back.
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. Install replacement bulb.
NOTE
The tab opposite the center spade connector of bulb fits the top notch in the reflector which points to the top of the reflector/lens.
2. Pivot the retaining clip over the bulb and press the ends into the retaining post.
3. On HDI models, replace the position lamp if necessary.
a. Pull the spade connectors from the bulb holder.
b. Pull the bulb holder from the reflector/lens.
c. Quarter turn the bulb to remove and replace.
d. Replace the bulb holder and mate connectors.
4. Install rubber boot with word TOP over top notch.
5. Press center ring down flush with base of bulb. Press air out of boot to seal bore of boot to bulb.
NOTE
Air will enter the rubber boot and raise the center ring above bottom of bulb.
6. Mate the bulb connector to the bulb.
7. Fit the adapter ring and the reflector/lens to the headlamp shell.
NOTE
  • The two notches on the circumference of the adapter ring will fit the two bulges on rim of headlamp shell.
  • A single tab on the circumference of the reflector will fit the notch on the inside of the adapter ring.
8. Rotate the trim ring clockwise to lock down on the reflector/lens. Install the trim ring screw and tighten.
9. 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)
10. Turn ignition on and test for proper operation.
11. After final assembly, align headlamp as described in Maintenance and Lubrication → Headlamp Alignment.
Figure 1. Headlamp Assembly
Table 1. Legend Headlamp Assembly
LEGEND NO.
COMPONENT
1
Screw
2
Nut
3
Trim ring
4
Lens
5
Bulb shield
6
Position lamp (HDI models)
7
Wire clip
8
Bulb
9
Rubber boot
10
Adapter ring
11
Connector [5]
12
Position lamp connectors
HDI models