WARNINGHandle 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
WARNINGTo 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.
- Remove main fuse. See Maintenance and Lubrication → Fuses.
- See Figure 1. Remove trim ring hardware (1). Remove trim ring (2).
- Remove mounting ring (3) and bumper, if equipped.
- Disconnect headlamp connector (8) from bulb (5).
- Remove rubber boot (6), if equipped, from back of headlamp lens (4).
- Remove wire retaining clip (7) from headlamp base.
- Remove bulb from headlamp assembly.
- For International Models Only: Rotate boot (10) one-quarter turn and remove bulb assembly from housing. Pull position bulb (9) to remove from boot.
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. | Install new bulb and assemble the headlamp components. | |
| 2. | For International Models Only: Install new bulb in boot. Install boot in housing and rotate one-quarter turn. | |
| 3. | Verify slots and tabs in headlamp and trim ring are aligned. | |
| 4. | Install rubber boot with word TOP at the top of the headlamp lens assembly. | |
| 5. | Connect the headlamp connector. | |
| 6. | Install bumper, if equipped. | |
| 7. | Install trim ring and hardware. | |
| 8. | 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) | ||
| 9. | Turn ignition on and test for proper operation. | |
| 10. | If necessary, align headlamp assembly. See Maintenance and Lubrication → Headlamp Alignment. |
| 1 | Trim ring hardware |
| 2 | Trim ring |
| 3 | Mounting ring |
| 4 | Headlamp lens |
| 5 | Bulb |
| 6 | Boot |
| 7 | Wire retaining clip |
| 8 | Headlamp connector |
| 9 | Bulb, position - HDI models only |
| 10 | Boot - HDI models only |
Figure 1. Headlamp Bulbs: Single Headlight