Bulb replacement
Hi/Lo beam
Note. Replace the bulb with the specified H4 halogen bulb.
1. Remove the trim ring.
- a. XL 883L/N/R, XR 1200X: See Figure 6-35. Remove the screw (1), nut (2)and the trim ring (3).
- b. XL 1200V/C/CP/CA/CB: See Figure 6-36. Remove the screw (1) and the trim ring.
![](https://motoinstruction.ru/img/harley/12/118273.jpg)
Figure 6-35. Headlamp assembly: XL 883L/N/R, XR 1200X: 1. Screw; 2. Nut; 3. Trim ring; 4. Lens; 5. Bulb shield; 6. Position lamp (HDI); 7. Bulb; 8. Wire clip; 9. Rubber boot; 10. Adapter ring; 11. Connector
![](https://motoinstruction.ru/img/harley/12/118274.jpg)
Figure 6-36. Headlamp assembly: XL 1200V/C/CP/CA/CB: 1. Screw; 2. Trim ring; 3. Lens; 4. Finger gasket; 5. Bulb shield; 6. Position lamp (HDI); 7. Bulb; 8. Wire clip; 9. Rubber boot; 10. Adapter ring; 11. Connector
2. Hold the lens and compress the release tabs of the bulb connector (11) to disconnect from spade terminals.
3. Pull the rubber boot (9) from back of the lens.
4. Compress the ends of the retaining clip (8) to release from the retaining tabs and pivot retaining clip back.
5. Remove and replace the bulb (7).
Note. The tab opposite the center spade connector of bulb fits the top notch in the reflector which points to the top of the lens.
6. Pivot the retaining clip over the bulb. Press the ends into the retaining tabs.
7. Install the rubber boot with the word TOP over the top notch. Press the center ring down flush with base of the bulb.
8. Connect the bulb connector to the bulb.
9. Install the lens.
- a. XL 883L/N/R, XR 1200X: Fit the adapter ring and the lens to the headlamp shell.
- b. XL 1200V/C/CP/CA/CB: With the finger gasket in place, fit the adapter ring and the lens to the headlamp shell.
10. Install the trim ring, screw and nut as necessary.
Position lamp: HDI
1. Disconnect the spade connectors from the position lamp bulb holder.
2. Pull the bulb holder from the lens.
3. Quarter turn the bulb to remove and replace.
4. Replace the bulb holder and connect the connectors.
Headlamp mounts
FASTENER | TORQUE VALUE | |
Headlamp upper bracket fasteners: XL 883L/R/N, XR 1200X | 120-192 in·lbs | 14-22 Nm |
Headlamp clamp nut: XL 883L/N/R, XR 1200X | 120-240 in·lbs | 14-27 Nm |
Headlamp mount: XL 1200X | 30-35 ft·lbs | 41-47 Nm |
Headlamp assembly: XL 1200X | 30-35 ft·lbs | 41-47 Nm |
Headlamp mount: XL 1200V/C/CP/CA/CB | 30-35 ft·lbs | 41-47 Nm |
Headlamp assembly: XL 1200X | 30-35 ft·lbs | 41-47 Nm |
Clutch cable guide: XL 1200C/C ANV/CP/CA/CB | 45-65 in·lbs | 4.0-7.3 Nm |
Headlamp visor: XL 1200C/C ANV/CP/CA/CB | 120-192 in·lbs | 14-22 Nm |
Mount: XL 883L/N/R, XR 1200X models
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
2. Install the headlamp assembly:
- a. See Figure 6-37. Mount the upper bracket (1) to the upper fork clamp with a washer (3) and fastener (4). Tighten to 120-192 in·lbs (14-22 Nm).
- b. XR 1200X: The headlamp assembly installs directly into the upper fork clamp (2).
![](https://motoinstruction.ru/img/harley/12/118275.jpg)
Figure 6-37. Headlamp mount: 1. Upper bracket (XL 883L/N/R); 2. Upper fork clamp (XR 1200X); 3. Washer; 4. Fastener; 5. Washer; 6. Lockwasher; 7. Nut; 8. Plug
3. Install the headlamp assembly with a washer (5), lockwasher (6) and nut (7) and hand tighten.
4. Install main fuse.
5. Align the headlamp. Final tighten to 120-240 in·lbs (1427 Nm).
6. Install the plug (8).
Mount: XL 1200X
1. Remove main fuse.
2. See Figure 6-38. Install the fastener (1), washer (2) and mounting post (3). Tighten to 30-35 ft·lbs (41-47 Nm).
![](https://motoinstruction.ru/img/harley/12/118276.jpg)
Figure 6-38. Headlamp assembly mount: XL 1200X: 1. Fastener; 2. Washer; 3. Mounting post; 4. Mount fastener; 5. Washer; 6. Washer; 7. Lockwasher; 8. Nut
3. Install the headlamp with the fastener (4), washer (5). Secure with the washer (6), lockwasher (7) and nut (8). Hand tighten.
4. Install main fuse.
5. Align the headlamp.
6. Tighten the headlamp assembly to 30-35 ft·lbs (41-47 Nm).
Mount: XL 1200V/C/CP/CA/CB
1. See Figure 6-39. Remove main fuse.
![](https://motoinstruction.ru/img/harley/12/118277.jpg)
Figure 6-39. Headlamp mount: XL 1200V/C/CP/CA/CB: 1. Mount; 2. Fastener; 3. Washer; 4. Fastener; 5. Washer; 6. Locknut
2. Install the fastener (2), washer (3) and mounting post (1). Tighten to 30-35 ft·lbs (41-47 Nm).
3. Assemble the washer stack (5) and fastener (4). Install the headlamp assembly. Hand tighten.
4. Install main fuse.
5. Align the headlamp.
6. Tighten the headlamp locknut (6) to 30-35 ft·lbs (41-47 Nm).
Visor: XL 1200C/C ANV/CP/CA/CB
1. See Figure 6-40. Install the clutch cable guide (1) with fastener (2). Tighten to 45-65 in·lbs (4.0-7.3 Nm).
![](https://motoinstruction.ru/img/harley/12/118278.jpg)
Figure 6-40. Headlamp visor: XL 1200C/C ANV/CP/CA/CB: 1. Clutch cable guide; 2. Fastener; 3. Visor; 4. Fastener; 5. Washer
2. Install the headlamp visor (3) with fasteners (4) and washers (5). Tighten to 120-192 in·lbs (14-22 Nm).