How to remove the headlight on a Suzuki Intruder VS1400

There are four screws in total on the exterior of the headlight, two inset screws which adjusts the position of the headlight (you do not need to remove these), then two screws that mount flush to the housing which allows you to remove the lens from the housing.

If you ever need to drill a screw out, start with a small drill bit, then go up a size gradually until you reach the size of the screw.

Remove the junction box from the three-prong connector and the two wires connecting the light to the wiring loom. This will allow you to completely disconnect the lens from the housing.

Removing the headlight housing

Next you’ll have to disconnect some of the wires to allow you to feed the loom through the back of the headlight housing and down through the frame. The wires should be colour coordinated but make sure you take note of what connects to what for re-assembly. When you have disconnected enough wires, feed the wiring loom out of the headlight housing. You may need to undo the fixing plate for a bit more manoeuvrability to allow you to release these wires.

Freeing the wiring

The wiring loom goes through the headlight, down under the yoke. There may be a clamp or metal plates that can be removed to give you more room to manoeuvre the wires.

Once you’ve removed the wiring, use an 10mm spanner to remove the two bolts holding the headlight housing to the frame.