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HEADLIGHTS

3K views 20 replies 9 participants last post by  Dasaliac03 
#1 ·
Well last night at about 10pm I finished installing my new '07 Harley Headlights...what an adventure!

In the end it really wasnt that difficult. For one, I'm glad I checked out some of the threads on this project, because the cutting diagram that came with my new headlights was not very helpful at all. Also I worked my dremmel so hard that the chuck lock sheared off!

And of course those new lights look ridiculously nice, so i'm pleased. And for $160 on eBay with harness included, not a bad purchase.

Here are my tips for those of you who are embarking on this project...

1) Use a rotozip to cut the grille pannel, a REAL rotozip. I killed my dremmel using rotozip bits in it. (having a jigsaw on hand helps alot)
2) You definately need a dust mask....its not plastic, its fiberglass and I was itching all over by the time the project was done.
3) Either buy a new set of light plugs or be very cautious when unhooking the old lamps: the plastic is very brittle and I had a few little corners and tabs break off.
4) No matter how well you cut, its a tight fit....make sure you mask the very corner of the fender, its kinda in the way.

Pics to come>>>>

-wes
 
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#2 ·
yeah it isn't as hard as you think it is going to be. It is a great upgrade!!
 
#3 ·
I have a question for anyone else that has put the 05 lights in. Does is seem to anyone that their lights shine a little bit too high? Mine fit perfect and aren't pointed high at all but for some reason the beams look high. The high/low works fine and highs aren't staying on or anything. Doesn't bother me any but seems to bother other drivers somtimes. haha
 
#4 ·
yeah I pointed mine down a little...
 
#5 ·
How did you manage that? I thought about it a little but ran out of time before I had to leave town again. Since the holes on the lights had to line up with the holes in the header panel I didnt really have any ideas. Was also thinking about just getting the 05 header panel to.
 
#10 ·
You really don't have any side to side adjustment, but as for the up and down, you should:

- Park as close as possible to a wall or garage door on flat ground.

- Use a small socket that fits snug over the star/torx adjustment screw to get both lights even.

- Mark where both lights shine on the wall.

- Back the truck up to about 25ft away and adjust both lights until they shine about 2-3 inches below where they did right in front of the wall.
 
#11 ·
Are you guys talking about how to adjust the old style headlights or the 05+? I put my lights in and haven't had a chance to mess with it and the truck is about 1800 miles away so I can't look at it. I'd just like to know what I need to do when I get back and have a chance to mess with the truck again.
 
#18 ·
This question is along the lines of adjustment for the guys that cut their header panels to install the '05-'07 lights. I'm assuming the '05-'07 lights have side-to-side and up/down adjustments on them standard. Do you lose any of that adjustment if you cut your header panel on the '99-'04 and install the '05 lights?
 
#19 ·
You don't lose any adjustment... you only have up and down.. .no side to side..
 
#20 ·
Do the '05-'07 trucks only have up/down adjustment then? So none of our trucks '99-'07 have side-to-side adjustments? I just picked up my '02 and haven't messed with it. So I don't know what adjustments it has. I just figured they would have both side-to-side and up/down.
 
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