[98 softtail]

Here are some pics showing the removal of the R side Headlamp motor and replacing the nylon gear. Look for the PICS a few replies down under Backyard Mechanics post.

What I didn't get to show was the reinstallation of the assembly, but I guess if you got this far just reverse it for putting it all back together.

Remove the dust cap that fits over the motor to get to the wheel screw that you would turn to manually open or close the headlamp assy. CCW to open.

Take note of the position of the Acutator arm when you remove it. When you replace the gear, position the shaft so that the flats on the shaft are in the same position, usually about a one o'clock position.

When replacing the assy hinge bolts, put a drop of loctite on the threads and don't tighten these little suckers too much, you want some play in the hinge.

Manually raise and lower the h/l assy a few times to make sure everything is working nice and easy.

Aword about gluing the cover back on the gear housing. I used JBWeld Quick on my other one and it seemes to be holding fine, but that was on the L side. The R side may have more torque on the cap and the JBWeld would not hold. I ended up using an old standby, Seal-All.

Clamp it and let it set and cure for about an hour. It seems to be working fine after about 20 times up and down.

I hope this helps if you ever need to replace these little buggers.

Joe B.

Sorry the slide show didnt work. AARRGGG!!!