Welcome to Our Community

Wanting to join the rest of our members? Feel free to sign up today.

Sign Up

How To Replace Your Headlight

Discussion in 'How-To' started by Gas Man, Apr 10, 2007.

Thread Status:
Not open for further replies.
  1. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Headlight Replacement "How To"

    Ok... guys...

    If you want to replace your bulb or the entire headlamp this is how.

    I am replacing my stock headlamp with a adjure wave cut black dot w/tri bar
    [​IMG]

    and a

    PIAA GTX HID bulb.
    [​IMG]


    So here's the stock setup that I have with some aftermarket hyper white bulb.
    [​IMG]
    [​IMG]
     
    Big D Florida and Tim like this.
  2. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    First unscrew the 1/16th inch allen screw under the headlight. There are 2 allens and 4 holes. The far back allen locks in a backing plate for the short lamp that BD uses. The allen towards the front holds the decrotive ring in place.

    [​IMG]


    Remove the decrotive chrome ring with your hands by spinning lefty loosy! If your fingers are slipping try one of those rubber jar openers or latex gloves.
    [​IMG]

    Now you'll find the retaining ring.
    [​IMG]

    Now they make a tool for it that most of us don't have. So I do the phillips head screwdriver and small hammer trick like so...
    [​IMG]
     
    Big D Florida likes this.
  3. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    You end up with everything coming out of the headlight. Here's the order...
    [​IMG]

    Put the decrotive and retaining ring aside.

    Unplug the headlight... here's the back side of your headlight.
    [​IMG]

    Now un-hook the clip
    [​IMG]

    While everything is out. Take your time and clean the threads on both rings and the headlight bucket. They will have neversieze on it with dirt. This will help in the re-essembly.

    If you are installing a new headlamp like me... read the second post. If not go to the third post.

    I swapped out my stock adjure headlight bulb like so.
     
    Big D Florida and WildBillNick like this.
  4. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Remove the stock bulb and install the new PIAA bulb.
    [​IMG]
    [​IMG]

    Here's what the new bulb looks like.

    [​IMG]
    [​IMG]
     
    Big D Florida and WildBillNick like this.
  5. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Now proceed to the 3rd post for re-assemble.

    Plug in the headlamp with the new headlight bulb and put back in the headlight bucket ensuring the rubber in flat.

    Like so.
    [​IMG]

    Now get some new Neversieze on the threads.
    [​IMG]

    Spin on the retaining ring while keeping the bottom of the lamp aligned with the set screw holes on the bottom of the bucket. This will ensure that the lamp is installed level.

    [​IMG]

    Make sure its in there tight. If it bounces around you will go thru bulbs fast. Not too mention it will rattle and drive you nuts.

    Now spin on the decretive ring. Once tight, re-install the allen set screw with loctite.
     
    Big D Florida and WildBillNick like this.
  6. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Clean your grubby prints off and BAM!

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
    Big D Florida and WildBillNick like this.
  7. Chopper Dave

    Chopper Dave SIICK!!!

    Joined:
    Apr 13, 2007
    Messages:
    8,451
    Likes Received:
    97
    Trophy Points:
    48
    Location:
    Michigan
    My Bike(s):
    2011 Ultra Limited
    First Name:
    Dave
    Hey Gas....I just ordered a pack of those PIAA GTX H-4 bulbs like you got. I am just going to swap out the bulb for now...then maybe later I will do the whole lamp housing like you did....hey at least I will have a spare bulb too!:whoop:
     
  8. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Yeah having the spare bulb is why I didn't sell off my second bulb. I like having the extra on hand.
     
  9. Chopper Dave

    Chopper Dave SIICK!!!

    Joined:
    Apr 13, 2007
    Messages:
    8,451
    Likes Received:
    97
    Trophy Points:
    48
    Location:
    Michigan
    My Bike(s):
    2011 Ultra Limited
    First Name:
    Dave
    Hopefully I will get it by Wednesday......then I could put it on before I ride dwon for my 500 service....or being that I am bringing the bike in...I might see if they could throw it in for me....but if not...no biggie....I can do it myself:D
     
  10. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Well if you don't already have it done... which I'm sure you do... they could put it in when they do the headlight wiring bullitin.
     
  11. Chopper Dave

    Chopper Dave SIICK!!!

    Joined:
    Apr 13, 2007
    Messages:
    8,451
    Likes Received:
    97
    Trophy Points:
    48
    Location:
    Michigan
    My Bike(s):
    2011 Ultra Limited
    First Name:
    Dave
    whats the headlight wiring bullitin?:willy_nilly:
     
  12. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    Nothing more than a wire extension of the headlight wire inside the headlight bucket. Most likely yours has been done. A quick call to Joe at Full Throttle and your project number will tell you for sure or not.
     
  13. Chopper Dave

    Chopper Dave SIICK!!!

    Joined:
    Apr 13, 2007
    Messages:
    8,451
    Likes Received:
    97
    Trophy Points:
    48
    Location:
    Michigan
    My Bike(s):
    2011 Ultra Limited
    First Name:
    Dave
    Thanks Chris....I will call him Wed. before I take it in Thurs. and see if mine was done or not. Now was this like a recall thing or something that they have been doing?
     
    #13 Chopper Dave, Apr 29, 2007
    Last edited: Apr 29, 2007
  14. Raywood

    Raywood The Pirate
    Staff Member Supporting Member

    Joined:
    Apr 5, 2007
    Messages:
    17,384
    Likes Received:
    720
    Trophy Points:
    113
    Location:
    Rainbow, CA
    My Bike(s):
    2014 KMW Regulator
    First Name:
    Ray
    Gas Man, you didn't include your turn signal shades on this post. I bought the lense covers for mine at the HD dealer and they don't fit. The clips are too short. I will take them back today and see if they have any larger ones or just return them.
    Thanks,
    Ray
     
  15. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    I didn't put up that thread... you're right.

    But I also didn't do that mod when I did this one.

    The lens themselves move inside the chrome visor.. are you sure yours aren't just pushed in or something strange? Cause mine fit on super easy.
     
  16. P8RIOT

    P8RIOT Well-Known Member
    Calendar Participant

    Joined:
    Apr 17, 2007
    Messages:
    2,187
    Likes Received:
    13
    Trophy Points:
    38
    Location:
    Kirkland, WA
    My Bike(s):
    2007 K-9
    As usual, Raywood is right on. I had the same experience. I bought mine at the local HD dealer, part number 69760-05, "Bullet Front Turn Signal Trim Ring," and the tabs are shorter than the ones on our Dogs. I was about to call Vickie when I saw this post.

    EDIT - OOPS - IGNORE ALL THAT! I just noticed that the INNER lens is separate from the "CHROME" ring. That is, the clear part with the tabs slides inside the chrome ring. When you take them out of the package, they are compressed together, so it looks like the tabs are shorter, and it is all one piece - but you just have to push out the center lens a bit, and VOILA - they fit just fine.

    BTW, the only difference in the HD packaging between FRONT and REAR is the light bulbs, not the lens covers. Front = 1157, and rear = 1156. You can also get the trim rings without the bulbs, but my HD dealer didn't have them, so I just got the kits they did have - with the bulbs.

    [​IMG]
     
    #16 P8RIOT, May 1, 2007
    Last edited: May 1, 2007
  17. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet

    Just like I said.... :2thumbs:
     
  18. Raywood

    Raywood The Pirate
    Staff Member Supporting Member

    Joined:
    Apr 5, 2007
    Messages:
    17,384
    Likes Received:
    720
    Trophy Points:
    113
    Location:
    Rainbow, CA
    My Bike(s):
    2014 KMW Regulator
    First Name:
    Ray
    Yep, just pushed mine out to so now they will clip in like they are suppose to.
    Thanks P8RIOT for the tip.

    Later,
    Ray
     
  19. Chopper Dave

    Chopper Dave SIICK!!!

    Joined:
    Apr 13, 2007
    Messages:
    8,451
    Likes Received:
    97
    Trophy Points:
    48
    Location:
    Michigan
    My Bike(s):
    2011 Ultra Limited
    First Name:
    Dave
    Looks like I will have to give Vickie a call and order a set.....those look sweet!:2thumbs:
     
  20. Gas Man

    Gas Man Cool isn't cheap
    Supporting Member Calendar Participant

    Joined:
    Apr 8, 2007
    Messages:
    15,047
    Likes Received:
    321
    Trophy Points:
    83
    Location:
    Metro Detoilet
    I got some good compliments the other day at the big dog dealer about this.
     
Thread Status:
Not open for further replies.

Share This Page