Removal High Beam, Low Beam
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
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
This headlamp assembly uses separate quartz halogen bulbs for the low beam and the high beam.
  1. Remove headlamp lens/reflector.
    1. See Figure 1. Remove screw (6) at bottom of chrome trim ring (7).
    2. Rotate ring counterclockwise a few degrees. Pull ring straight forward to remove.
    3. Remove screws (4) securing retaining ring (5).
    4. Remove retaining ring and the halogen lens/reflector (8).
  2. See Figure 1. Disconnect wire harness connector (11 or 12) from the burned out bulb.
  3. Rotate bulb a quarter turn counterclockwise to remove from the reflector/lens.
Position Lamp: HDI
  1. See Figure 1. Disconnect the connector (10) from the position lamp socket (1).
  2. Rotate socket a quarter turn counterclockwise to remove.
  3. Remove the bulb (9) from the socket.
  4. Install the bulb in the socket.
  5. Install the socket in the reflector/lens.
  6. Install the connector.
Installation High Beam, Low Beam
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. See Figure 1. Insert a new bulb (2 or 3) into reflector/lens (8). Rotate the bulb a quarter turn clockwise.
2. Connect the wiring harness connectors (11 or 12) to the bulbs.
3. Install the reflector/lens.
a. Capture the reflector/lens in the retaining ring (5).
b. Install the screws (4). Tighten to 1–2 N·m (9–18 in-lbs).
c. Verify that the rubber seal and retaining springs are in place inside the trim ring.
d. With the trim ring (7) rotated a few degrees counterclockwise, push trim ring straight onto headlamp.
e. Rotate the ring clockwise until the trim ring screw hole is aligned with the threaded hole in the mounting ring. Install the screw (6). Tighten to 1–2 N·m (9–18 in-lbs).
1Position lamp socket
2High beam bulb
3Low beam bulb
4Screws (3)
5Retaining ring
6Screw
7Trim ring
8Refector/lens
9Position lamp bulb
10Position lamp connector
11High beam connector
12Low beam connector
Figure 1. Halogen Headlamp