Head light wont budge

[Medic40]

Anyone know why the headlight so tough to get off. I have an 05 chopper. I cant seem to budge the headlight assembly when I take the decorative covers off. Can anyone explain to me this deal. I put the screw driver at an angle and tap for it to turn loose but its not moving for me.
Thanks
:bang:

 

[BigDogBro1]

Don't understand your explanation that well.

If your headlight bucket assembly is like my 2007 then here's some help.

Are you talking about the outer trim ring and the inner headlight retaining ring. Both are held in with small setscrews on the bottom side of the bucket. The screws need to be removed first then the rings should both unscrew. It's more difficult without the tool. Don't over-tighten the screws at reassembly as there are only 3-4 threads in the bucket. If no lock screws are used you risk the chance of loosing the trim ring while riding.

The inner ring has an o-ring on the back side of it and if it's never been removed before then it could be sticking onto the glass. Try some silicone spray with a nozzle tube behind the retaining ring.

If either of the rings are not evenly unscrewed they can cross-thread and jam, so be patient and work them out slow.

The headlight shoud loosen a fall free when the retaining ring is removed.

Here is a drawing for a retaining ring removal tool:

 

[Medic40]

Thank you, just made my day a lot easier.

 

[aspen874]

Andrew, you're going to have to start charging consulting fees LOL

 

[Letbigdogintocanada]

Dump some wd-40 type of lube on the thread,it's easier to unscrew if its seized,good luck

 

[liferider]

Had this problem a while back, but it was the metal inner ring which holds the glass in place that was difficult to remove. I finally inserted 2 small T-handle allen wrenches at 180* and turned them at the same time.