2007 Buell Lightning: Electrical 7-43
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HEADLIGHT BULBS
Removal
1. Remove seat. See 2.44 SEAT.
1WARNING1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a).
2. Disconnect negative battery cable.
1CAUTION
Handle bulb carefully and wear eye protection. Bulb con-
tains Halogen gas under pressure, which, if not handled
carefully, could cause serious eye injury. (00062a)
CAUTION
Never touch the quartz bulb. Fingerprints will etch the
glass and decrease bulb life. Grab the bulb with paper or
a clean, dry cloth. Failure to do so could result in bulb
damage. (00210a)
3. Remove windscreen. See2.43 WINDSCREEN.
4. Remove headlight housing fasteners.
5. Disconnect headlight connector [38] and remove head-
light assembly.
6. See Figure 7-51. Remove rubber boot from headlight
housing.
7. Unplug headlight bulb connectors (3) and/or (4).
8. Release bulb holder (2) from headlight housing clips.
9. Pull bulb housing from headlight housing.
Installation
NOTE
Not using the specified bulb may cause charging system prob-
lems.
1CAUTION
Handle bulb carefully and wear eye protection. Bulb con-
tains Halogen gas under pressure, which, if not handled
carefully, could cause serious eye injury. (00062a)
CAUTION
Never touch the quartz bulb. Fingerprints will etch the
glass and decrease bulb life. Grab the bulb with paper or
a clean, dry cloth. Failure to do so could result in bulb
damage. (00210a)
1. See Figure 7-51. Align tabs on bulb (5) with tabs on
headlight (1). Insert bulb.
2. Close the bulb holder (2).
3. Connect the headlight bulb connector.
NOTE
If the rubber boots are not installed correctly the wiring har-
nesses can contact the edge of the forward frame mount. The
wiring harness guides must be installed at a 20 degree angle.
4. See Figure 7-53. Install rubber boot.
a. When installing the rubber boots on the back of the
headlight housing be sure to align the harness
guides or spigots with the casting marks on the
headlight housing.
b. When the spigots are aligned with the casting marks
the wiring harness will be at approximately 20
degrees.
5. Connect headlight connector [38].
6. Install headlight housing fasteners and tighten to 48-72
in-lbs (5.4-8.1 Nm).
7. Install windscreen. See 2.43 WINDSCREEN.
8. Connect negative battery cable.
1WARNING1WARNING
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider can
result in death or serious injury. (00316a)
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