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. Remove the trim ring.
    1. XL 883L/N/R, XL 1200N/X, XR 1200X: See Figure 1. Remove screw (1), nut (2) and headlamp trim ring (3). Refer to Table 1.
    2. XL 1200C/CP/V: See Figure 2. Remove screw (1) and headlamp trim ring (2). Refer to Table 2.
  3. Hold headlamp reflector/lens and compress release tabs on sides of bulb connector (11) to pull connector from the bulb (7) spade terminals.
  4. Remove headlamp lens and metal adapter ring.
  5. Pull rubber boot from back of the lens.
  6. Press ends of retaining clip (8) to unhook from notched retaining tabs and pivot retaining clip back.
  7. Remove the bulb.
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 the replacement bulb.
NOTE
Fit the tab opposite the center spade connector of bulb to the top notch in the reflector.
2. Pivot the retaining clip over the bulb and press the ends into the retaining post.
3. Install rubber boot with word TOP over top notch.
4. 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.
5. Connect the bulb connector to the bulb.
6. Install the lens.
a. XL 883L/N/R, XL 1200N/X, XR 1200X: Fit the adapter ring and the reflector/lens to the headlamp shell.
b. XL 1200C/CP/V: With the finger gasket in place, fit the adapter ring and the reflector/lens to the headlamp shell.
NOTE
  • Fit the two notches on the circumference of the adapter ring to the two bulges on rim of headlamp shell.
  • Fit the single tab on the circumference of the reflector to the notch on the inside of the adapter ring.
7. Rotate the trim ring clockwise to lock down on the reflector/lens. Install the trim ring screw, nut as necessary and tighten.
8. Install the 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. Test operation of the headlamp.
10. Align the headlamp. See Maintenance and Lubrication → Headlamp Alignment.
Position Lamp: HDI
  1. Replace the position lamp if necessary.
  2. Pull the spade connectors from the bulb holder.
  3. Pull the bulb holder from the reflector/lens.
  4. Quarter turn the bulb to remove and replace.
  5. Replace the bulb holder and mate connectors.
Figure 1. Headlamp Assembly: XL 883L/N/R, XL 1200N/X, XR 1200X
Table 1. Legend Headlamp Assembly: XL 883L/N/R, XL 1200N, XR 1200X
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
Figure 2. Headlamp Assembly: XL 1200C/CP/V
Table 2. Legend Headlamp Assembly: XL 1200C/CP/V
LEGEND NO.
COMPONENT
1
Screw
2
Trim ring
3
Lens
4
Finger gasket
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