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.
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.	See Figure 2. Press ends of retaining clip to unhook from notched retaining tabs and pivot retaining clip back.
	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)
7.	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.
8.	Pivot the retaining clip over the bulb and press the ends into the retaining post.
9.	For XL 883C/XL 1200C models, remove and fit a replacement rubber finger gasket if necessary. NOTE The smaller single notch of the rubber finger gasket will fit over the top notch of the reflector/lens.
10.	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.
11.	Install rubber boot with word TOP over top notch.
12.	Press center ring down flush with base of bulb. Press air out of boot to seal bore of boot to bulb and boot flange to rubber finger gasket (XL 883C/XL 1200C). NOTE Air will re-enter the rubber boot and raise the center ring above bottom of bulb.
13.	Mate the bulb connector to the bulb.
14.	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. On XL 883C/XL 1200C models, the four fingers of the rubber finger gasket are installed between the adapter ring and the reflector/lens.
15.	Rotate the trim ring clockwise to lock down on the reflector/lens. Install the trim ring screw and tighten.
16.	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)
17.	Turn ignition on and test for proper operation.
18.	After final assembly, align headlamp as described in Maintenance and Lubrication → Headlamp Alignment.

1	Screw
2	Nut
3	Trim ring
4	Lens
5	Rubber finger gasket
6	Position lamp (HDI models)
7	Bulb
8	Bulb shield
9	Rubber boot
10	Wire clip
11	Adapter ring
12	Connector

Figure 1. Headlamp Assemblies

Figure 2. Wire Retaining Clip (Typical)