Removing headlight assembly - need some help

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Jan 10, 2009 | 04:15 PM

AmmoDan

Thread Starter

Cruiser

Joined: Dec 2007

Posts: 128

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From: Minot, ND

Removing headlight assembly - need some help

I'm taking my headlight assembly off the Fat Bob to send it off to the powdercoater - problem is, I'm having a tough time getting to the headlamp housing connector. The service manual (pg. 8-16) tells me to loosen the fuel tank.

Am I supposed to completely pull off the tank to detach this thing? I can't seem to get the tank lifted enough to see where the harness is.

Also, is there some way to remove the wiring from the headlamp housing? It seems to me that you have to actually take the wires out from either the headlamp connectors or the headlamp housing connector.

I know some folks have done this before - any help is appreciated.

Jan 10, 2009 | 04:25 PM

Airborne350G

Club Member

Joined: Jun 2007

Posts: 3,435

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From: Living in open carry state :D

The connector can be reached by removing the plastic cover under the neck of the bike. There are two tabs on each side. Once removed you will be able to pull the connector out of the neck. You can also just remove the rubber grommet that the headlight wires run through. Well that is how I did it on my Wide Glide.

Jan 10, 2009 | 04:47 PM

benwiggin2

Road Master

Joined: Jul 2008

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From: The wild, wild, west.

Dan
1) Follow the wire from your headlight back into the right hand side of the neck of the frame.
2) Pull out the rubber grommet that the wire goes through.
3) The connector is just inside the frame. Pull the wire out a couple of inches and you'll be able to disconnect the connector.
4) Unbolt the headlight block just above the lower triple tree carefully.
5) Take the headlight over to your workbench, or in my case, the washing machine.

Jan 10, 2009 | 06:34 PM

AmmoDan

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Cruiser

Joined: Dec 2007

Posts: 128

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From: Minot, ND

Thanks for the replies. I'll have to try again tomorrow (its below freezing up my way - no heat in the garage). Ben, I was thinking of your headlight mod when I was trying to get the housing off and was having some difficulty. I knew it wasn't impossible!

Thanks again.

Jan 11, 2009 | 02:44 PM

AmmoDan

Thread Starter

Cruiser

Joined: Dec 2007

Posts: 128

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From: Minot, ND

Thanks for the advice, ben - it worked.

Lesson learned - cold rubber is more likely to tear than bend (it hasn't been above 25 in about a month now). Looks like a new grommet is in my future.

Jan 11, 2009 | 09:02 PM

08fxdf43202

Road Warrior

Joined: Apr 2008

Posts: 1,998

Likes: 14

From: Central Ohio

I've just finished a handlebar swap & relocated the turn sigs on my Fat Bob. I left the rubber gromets off of both sides... I think it looks better w/o em.