HEADLIGHT ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. REMOVE FRONT SIDE MARKER LIGHT BULB (w/ Side Marker Light)

   
   

   1. 

      Turn the headlight cord with the front side marker light bulb as shown in the illustration to disconnect it.

   2. Remove the front side marker light bulb from the headlight cord.

2. REMOVE FRONT TURN SIGNAL LIGHT BULB

   
   

   1. 

      Turn the headlight cord with the front turn signal light bulb as shown in the illustration to disconnect it.

   2. Remove the front turn signal light bulb from the front turn signal light cord.

3. REMOVE HEADLIGHT CORD

   
   

   1. 

      Disengage the claw and 3 clamps to remove the headlight cord from the headlight assembly.

4. REMOVE HEADLIGHT COVER (for Halogen Headlight)

   
   

   1. 

      Turn the headlight cover as shown in the illustration to remove it.

5. REMOVE HEADLIGHT BULB (for Halogen Headlight)

   
   

   1. 

      Disconnect the connector.

   2. 

      Turn the headlight bulb as shown in the illustration to remove it.

      Note

      Do not touch the bulb glass.

6. REMOVE HEADLIGHT LENS

   
   

   1. 

      Text in Illustration

      *a	Screw
      *b	"TORX" Screw

      Remove the 5 screws.

   2. Using a T20H "TORX" driver, remove the "TORX" screw.

   3. 

      Remove the 3 screws.

   4. 

      Using a dryer, heat the backside of the headlight assembly.

      Note

      If the headlight is heated unevenly, it will deform or melt.

   5. 

      Disengage the 6 claws and remove the headlight lens.

      Note

      
      

      • Wear rubber gloves when handling the headlight lens.

      • Do not touch the lens or the aluminum surfaces with bare hands.

      • If there are fingerprints on the aluminum surfaces, wipe them off with a soft cloth.

      • If there are fingerprints on the inner side of the headlight lens, replace the headlight lens.

      • Do not allow dirt or foreign matter to get on the inner side of the headlight lens.

      Tech Tips

      If the headlight lens cannot be removed even after heating, using a screwdriver with its tip wrapped with protective tape, lift the headlight lens. Be careful not to damage the headlight lens and housing.

   6. 

      Disconnect the connector.

7. REMOVE HEADLIGHT LENS GASKET

   
   

   1. 

      Remove the headlight lens gasket from the headlight unit assembly.

8. REMOVE HEADLIGHT UNIT

   
   

   1. 

      Disengage the clamp.

   2. Remove the 7 screws and protector.

   3. 

      Remove headlight unit.

      Note

      
      

      • Do not touch the headlight unit or the aluminum surfaces with bare hands.

      • If there are fingerprints on the aluminum surfaces, wipe them off with a soft cloth.

9. REMOVE LIGHT CONTROL ECU

   
   

   1. 

      Disconnect the connector.

   2. Remove the 2 screws and light control ECU from the headlight unit as shown in the illustration.

10. REMOVE LIGHT CONTROL ECU (for LED Headlight)

    
    

    1. 

       Disconnect the connector.

    2. Remove the 2 screws and light control ECU from the headlight unit as shown in the illustration.

11. REMOVE HEADLIGHT SWIVEL MOTOR

    
    

    1. 

       Remove the 2 screws and reflector from the body assembly.

    2. 

       Disconnect the 2 connectors and disengage the 2 claws.

    3. Before removing the unit assembly A, measure and note the dimensions A and B in the illustration.

    4. 

       Text in Illustration

       *a	Aiming Screw

       Rotate the 2 aiming screws counterclockwise.

    5. Remove the unit assembly A from the body assembly.

    6. 

       Remove the screw.

    7. Move the headlight swivel motor as shown in the illustration and remove it from the unit assembly A.

    8. 

       Remove the attachment.