Tutorial: Headlight insert, Harley-Davidson
According to the manufacturer, the new LED lamp does not fit the old Dyna mount (#68787-10) and you need 5-3/4 in. LED Headlamp Housing Kit (#67700455 and #67746-11) to make this work. It turns out that it can be done without changing the housing. I was ready to try and put in some work after purchasing this insert used at a very good price (50$) and in great condition.
The obstacle is a small part of the heat radiator at the back of the lamp. Small corner, one side only.
Just cut it off (for example, with a Dremel) and the lamp will fit into the case. See the left corner cut - near the bolt hole.
In addition, modification of the power supply was required to use the old plug.
Now just install your new LED Daymaker into your old headlight housing.
Expert words
Always make sure for fitment for your bike’s year and model. It may require some modification of the connectors or wiring, rarely to the mounting but sometimes even when at first glance size and shape is the same they may not be plug and play. Always adjust level afterwards though it may change during installation, also check for proper operation.
Thijs Van Daalen, Master Service Technician, Netherlands