How to remove and reinstall your headlight


Step-by-step tutorials on how to maintain and fix your GL1200
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WingAdmin
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How to remove and reinstall your headlight

Postby WingAdmin » Thu Dec 11, 2014 10:41 am



Taken from the service manual:

REMOVAL
With fairing:
Rotate the right and left rear view mirrors on mirror mounts about 90° as shown.
Remove the rear view mirrors by removing the attaching bolts.

Without fairing:
Remove the right and left blind covers from the fairing.
Remove the windshield trim mount bolts.
GL1200 Headlight replacement 1
GL1200 Headlight replacement 1


Remove the windshield trim by lifting it with screwdriver.
NOTE: Protect the headlight with shop towel to prevent damaging the headlight lens.
GL1200 Headlight replacement 2
GL1200 Headlight replacement 2


Remove the headlight garnish.
Remove the headlight mounting bolts.
Remove the headlight garnish bracket and trim holder.
GL1200 Headlight replacement 3
GL1200 Headlight replacement 3


Remove the three screws and disconnect the beam adjusting cable from the headlight.
Disconnect the headlight coupler and position light wires and remove the headlight.
GL1200 Headlight replacement 4
GL1200 Headlight replacement 4


INSTALLATION
Connect the headlight coupler, position light wire and beam adjusting cable to the headlight.
Install the headlight, trim holder bracket and garnish bracket.
Install the headlight garnish.
GL1200 Headlight replacement 5
GL1200 Headlight replacement 5


Latch the windshield trim into position by pushing it down on top.
GL1200 Headlight replacement 6
GL1200 Headlight replacement 6


With fairing:
Install the right and left rear view mirrors.
Install the boots onto mirrors.
Adjust the headlight beam if necessary.

Without fairing:
Install the windshield trim mount bolts and tighten it securely.
Install the right and left blind covers.
Adjust the headlight beam if necessary.
GL1200 Headlight replacement 7
GL1200 Headlight replacement 7



Kris
Posts: 4
Joined: Fri Jun 05, 2015 4:17 pm
Location: Big Cedar Ontario Canada
Motorcycle: 1987 GL1200 Interstate

Re: How to remove and reinstall your headlight

Postby Kris » Fri Jun 05, 2015 4:51 pm

I have an 1987 GL1200, and the lights are not bright enough for me at night. I put running lights on, from a Harley, and it drained my battery. Any suggestions as to a fix for this. I was going to upgrade the bulb, will that be enough?

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WingAdmin
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Posts: 17050
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: How to remove and reinstall your headlight

Postby WingAdmin » Mon Jun 08, 2015 11:04 am

Kris wrote:I have an 1987 GL1200, and the lights are not bright enough for me at night. I put running lights on, from a Harley, and it drained my battery. Any suggestions as to a fix for this. I was going to upgrade the bulb, will that be enough?


You might also want to check the reflector itself. Some of the GL1200's have a degraded reflector, where the "shiny bit" on the back has become dim or melted away, and is no longer actually reflecting light out the front of the light.

If the reflector is in OK shape, the best thing you could really do is to replace the bulb with a HID kit. They put out a tremendous amount of light, drawing less power than the original OEM bulb.

Kris
Posts: 4
Joined: Fri Jun 05, 2015 4:17 pm
Location: Big Cedar Ontario Canada
Motorcycle: 1987 GL1200 Interstate

Re: How to remove and reinstall your headlight

Postby Kris » Mon Jun 08, 2015 12:29 pm

Thanks, I will check the reflector. I was going to go to the blue light bulb. Will that cause issues, or must I put the kit in?

User avatar
WingAdmin
Site Admin
Posts: 17050
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: How to remove and reinstall your headlight

Postby WingAdmin » Mon Jun 08, 2015 1:04 pm

Kris wrote:Thanks, I will check the reflector. I was going to go to the blue light bulb. Will that cause issues, or must I put the kit in?


I don't know that it will help your night vision much - nowhere near like what a HID bulb would do. HID bulbs will put out triple the brightness and last at least three times as long.

Kris
Posts: 4
Joined: Fri Jun 05, 2015 4:17 pm
Location: Big Cedar Ontario Canada
Motorcycle: 1987 GL1200 Interstate

Re: How to remove and reinstall your headlight

Postby Kris » Mon Jun 08, 2015 2:56 pm

Thanks, that is good to know, and I will check into them. Night vision is my concern. It is very limited with the old lights, and I live north, andin the middle of deer country.

User avatar
WingAdmin
Site Admin
Posts: 17050
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: How to remove and reinstall your headlight

Postby WingAdmin » Mon Jun 08, 2015 2:58 pm

Kris wrote:Thanks, that is good to know, and I will check into them. Night vision is my concern. It is very limited with the old lights, and I live north, andin the middle of deer country.


Honestly, the difference between the original headlight and a HID light is like night and day.

Talk to Cyclemax - they have a HID kit for the GL1200 that is fairly easy to install. I put the same kit in my wife's PC800, and the difference is huge:

http://cyclemax.com/inc/sdetail/gl1000_ ... 105/218610


Kris
Posts: 4
Joined: Fri Jun 05, 2015 4:17 pm
Location: Big Cedar Ontario Canada
Motorcycle: 1987 GL1200 Interstate

Re: How to remove and reinstall your headlight

Postby Kris » Mon Jun 08, 2015 3:17 pm

Thak ou so much, this has been very helpful, and I am going to get one of these lights for my bike. I love to take her out at night. It will now be a pleasure. Kris




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