Lights

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Headlight

Aim Adjustment

Adjust the vertical headlight aim by turning the adjusting screw with a #2 Phillips screwdriver. On level ground the high beam should be just below horizontal with a rider onboard.

Removal

Remove the inner covers on the 2002 – 2003 650 models and all 700 models. See the Inner Covers topic for more information.

Remove the two (one per light) headlight mountings screws from each side of the front bumper.

Unplug the two 3-pin headlight connectors.

Remove the three screws that hold the headlight to the front fender with a #2 Phillips screwdriver.

Remove the headlight from the front fender.

Bulb Replacement

Remove the two headlight bolts and washers with an 8 mm socket.

Loosen the aim adjusting screw with a #2 Phillips screwdriver.

Remove the adjusting screw nut.

Remove the spring and adjusting screw.

Remove the headlight body.

Unplug the headlight bulb connector.

Lift off the rubber dust cover.

Push and turn the bulb holder counterclockwise to free it. Remove the bulb holder with spring.

Remove the headlight bulb and replace if needed. Do not touch glass with bare hands.

Fit the headlight bulb into place with the tang entering the notch.

Install the bulb holder with spring. Push down and rotate the holder clockwise to lock it into place.

Install the rubber duct cover so that its TOP mark faces up.

Plug in the headlight bulb connector.

Install the headlight body.

Install the aim adjusting screw and spring.

Install the aim adjusting nut.

Install the two headlight bolts and washers with an 8 mm socket.

Installation

Fit the headlight into the front fender. Install the three screws that hold the headlight to the front fender with a #2 Phillips screwdriver.

Plug in the two 3-pin headlight connectors.

Install the two (one per light) headlight mountings screws through each side of the front bumper.

Taillight

Bulb Replacement

Remove the two lens screws with a #2 Phillips screwdriver.

Remove the taillight lens.

Push in and turn the bulb counterclockwise to remove it. Replace the bulb as needed.

Return the taillight lens and install the two screws. Do not over tighten the screws and break the lens.

Removal

Remove the rear fender. See the Rear Fender topic for more information.

Remove the taillight bulb socket from inside the rear fender. Remove the taillight mounting screws with a Phillips screwdriver.