I had the dealer swap out my headlight when I purchased the bike 4 months ago. One day while riding along last week, the whole headlight just popped right out of the housing. As I was reseating it- I didn't see anything that actually secures the headlight inside of the can. The only thing that seems to keep it inside the can is the metal frame that you tighten around the outside of the headlight. Am I missing something, or should there be a screw to mount the headlight into the can before placing the trim ring on the outside and screwing it on? It seems like the force of the light just wants to pop this off.

 

Nope, it just sits inside loose. The trim ring is the only thing that holds it from coming out (bad design, but I understand why as it's a universal replacement headlight).

 

Ive had my daymaker in since day 1 and almost 5000 miles on my breakout and its still sitting solid. Once its in there its really secure.

 

I guess its possible they didnt tighten the trim ring enough....I put mine in myself and had no issues.

 

Thx for the feedback. It also popped out after i reset it one time, and it just seems like it really has a lot of pressure pushing out of the can, and there's not a lot of "lip" for the trim ring to grab onto- making me nervous...

 

It may be worth taking it back in to at least get the issue recorded (since they did the install). Can't imagine it's too good for the connectors or maybe your paint to have it popping out.

I doubt you can make the lip any more pronounced on the can but maybe you can get the edge of the ring bent a little to give more grab.

 

You're probably right- but I really don't want to take this into the dealer for something so minor. The only saving grace is that the connectors kept the headlight from dropping on the ground (or my fender).

I can also ride with my 1/4 fairing on to keep it seated back in there as well until i get there.

 

There are a number of possible reasons for the problem the OP is experiencing:

- The Daymaker kit comes with a "gasket ring" that is used on SOME models of bikes. That ring is NOT to be used on the Breakout. It is only to be used on models where there was ORIGINALLY a gasket ring. If you try to put it in on a Breakout, it creates pressure that tries to eject the headlight

- The metal ring (NOT the chrome external trim ring) that goes in BEFORE the Daymaker has to be put in (a) correct side forward relative to the headlight shell and (b) specifically aligned with the slots and "speed bumps" in the headlight shell. If it is put in reverse side forward, or if it is not precisely aligned, the headlight will be too far forward and the trim ring won't properly engage the headlight housing. The best way to achieve this is to place the metal ring in roughly first (correct side forward), thread the electrical headlight connector through it,plug the Daymaker into the connector, and THEN take the time to precisely place the metal ring where it should be, and then GENTLY fit the Daymaker into it without disturbing the ring. THEN, while HOLDING the Daymaker in position, insatll the trim ring with the other hand. Make sure the trim ring & Dyamker are pointing straight forward. It is very easy for them to get "cocked" so they point a bit left or right. If they are cocked, no way will the chrome trim ring secure properly!

Once everything is aligned correctly, gently insert the bolt that tightens the chrome trim ring, and hold the locknut in its proper place (don't crossthread!). Tighten the trim ring while holding the Daymaker steady so it does not move.

When, done, the little "speed bumps" in the headlight shell should all look the same. If one is covered and the others are not, that means the Daymake and metal ring moved, and you need to restart the whole process.

The whole installation process is one of those things that a guy at the HD factory can probably do in his sleep, but since each of us gets to only do it ONCE, and the HD daler technicians only do it a handful fo times each year maybe, it's a slow sometimes frustrating process.

The end result though is VERY much worth it. The Daymaker really is a fantastic headlight.

Jim G

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Jim: Thanks for the info- This could be my issue then. To confirm- By the "gasket ring", you're talking about that thin rubber strip that goes all the way around the circumference of the outside of the can between it and the back of the light? Mine does have this in there- so is there any documentation where it states that the breakout should not use this (so I can take it to my dealer and show them how they f'd up)?

And is there any way to know for sure how the inner metal ring is supposed to go in (besides trial and error)- and speaking of that piece- should the little prongs face towards the outside of the light, or face inside the can (currently i have them facing out)- but again- I do have a lot of pressure and fitting the light inside of the can was VERY tight- and maybe the first part of the rubber ring is my issue.

I really appreciate the detailed response.

 

You are correct: the gasket I spoke of is the thin rubberery gasket ring that comes with the Daymaker.

The instructions that come with Daymaker, and which are also in pdf format on the HD product website page for the Daymaker, clearly state that the rubber strip gasket should only be used on models where sucha gasket is already in place, and not on models where there is no pre-existing gasket. Naturally, the technicians don't read the instructions, because "real men don't need no stinkin' instructions".

The Breakout model does NOT have a pre-existing gasket ring, so no gasket should be used with the Daymaker.

On models where there WAS a pre-existing gasket ring, the intent is that the NEW gasket that comes with the Daymaker be used instead of the old gasket, presumably because its diemensions or other attributes are different than the old gasket.

The Daymaker instructions are pretty crappy as far as the inside metal ring is concerned. Basically, you have to "figure it out". The good news is that if you have it reversed (wrong side facing forward), or have it misaligned with the punched "speed bumps" in the headlight housing shell, the whole assembmly simply won't "fit". Once you get it right, you'll both see and feel that it is obviously correct. I cannot remember which way the metal ring faces - it has simply been too long since I did the install.

Mine has been secure now for over 1400 miles, so I figure I got it in there correctly.

Jim G