Ok, hopefully this saves someone the agony of trying to reinvent the wheel - aka replace the center light unit should your center units crack due to a rock like mine did.
What I started with:
What You'll Need:
- Replacement Center Unit : Purchase single unit on Amazon for $116 or Purchase double unit from Polaris for $322 (ya know - if you like wasting money and sh*t) Both are Hella Brand and include a replacement bulb
- A 10mm Ratcheting Combination Wrench - $7.69 from Home Depot (you'll need the ratcheting part)
- A Pair of Pliers
- A Screw Driver
Step 1: Disconnect both headlight units.
Step 2: Remove the Entire Center Headlight Housing by undoing four bolts (#12 in this diagram). DO NOT try to remove just the headlight. Grab that 10mm ratcheting combination wrench and remove the 4 bolts holding the headlight units in place. The two bottom bolts will be impossible to ratchet all the way off without getting your tool stuck between the hood support bar, so you'll have to manually remove it (learned the hard way). You may curse a lot, but you should not have to remove the horn so quit ya b*tchin.
Step 3: Remove the Damaged Headlight from the housing. The black things holding the headlight into the housing are some sort of Romanian quick release clamps. Don't know the real name, but use the flat nose pliers to pinch the release tabs on the three screws holding the headlight in and it should pop out. Once out of the housing, remove the black Romanian quick release clamps and use a screw driver to remove the screws if ya wanna salvage the parts. If not - just throw the unit out screws / caps and all.
Don't forget to remove the old bulb from the broken unit - future free bulb replacement, yay!
Step 4: Prepping the Replacement. The replacement headlight comes with an extra screw you won't need, so don't fret - it's like Ikea, some parts aren't necessary (maybe). Screw the bolts into the new headlight BEFORE you put the black caps on - you won't need to screw it in all the way, just match the picture up top - about half way, then pop the three caps on and shove it back into place.
Step 5: Reinstalling the Housing. New bulb in housing, return to your noble steed and reassemble using the 10mm wrench. Remember - those two bottom bolts are a b*tch, so you'll have to manually wrench it in without using the ratchet until you have clearance.
* I didn't need to adjust the angle of the headlight beam but if you do, I think they teach ya how in the owner's manual.
