Removal
  1. Remove screw at bottom of headlamp door (chrome ring). Remove headlamp door.
  2. See Figure 1. Remove screws securing headlamp assembly.
  3. Remove headlamp connector from headlamp bulb.
Figure 1. Headlamp Retaining Screws (typical)
Bulb Replacement
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)
NOTE
The headlamp uses a replaceable quartz halogen bulb which is very delicate and must be handled with care.
1. Remove headlamp assembly.
2. Remove rubber boot at back of housing.
3. See Figure 2. Release wire retaining clip (1) from retainer (2). Swing wireform out of the way.
NOTE
It may be necessary to loosen retainer screw 1/2-1 turn to release wireform.
WARNING
Handle bulb carefully and wear eye protection. Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062b)
4. Remove and discard bulb.
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)
5. Install new bulb. Align the tab on the bulb with the notch in the headlamp housing.
6. See Figure 2. Rotate wire retaining clip (1) into place and latch under lip of retainer (2).
NOTE
If retainer screw was loosened to release wire retaining clip, hold retainer in place and tighten screw until snug. Verify that reflector cone is still centered under decorative logo. If it is not, loosen retainer screw and repeat step until the proper results are achieved.
7. Install rubber boot at back of housing.
8. HDI models: Rotate position lamp bulb retainer 1/4 turn counterclockwise to remove. Replace bulb and install bulb retainer in lamp housing.
9. Install headlamp assembly.
1Wire retaining clip
2Retainer
Figure 2. Wire Retaining Clip
Installation
1. Install headlamp connector on headlamp bulb.
2. Install headlamp assembly and tighten screws to:
a. Non-fairing equipped: 1–2 N·m (9–18 in-lbs).
b. Fairing equipped: 2.5–3.6 N·m (22–32 in-lbs).
3. Fit the headlamp door spring into slot at top of headlamp housing and secure the headlamp door (chrome ring) with screw. Tighten to 1–2 N·m (9–18 in-lbs).