Headlight Bucket

[Ron Baker]

I'm getting ready to tear down my headlight bucket so I can paint it. Is the anything special to doing that as it looks like a rats nest in there?
Thanks for any suggestions
Ron

[Airbear]

Think of it as an adventure. Take lots of photos of the journey. Make notes. Label anything you are uncertain about.

You should find that the colour coding works. Work methodically. Use haemostats or forceps or long-nose pliers to pull the terminals off. (SteveD might be along to post a pic of the ultimate tool.)

If a PO has added anything or stuffed around with wires you will need to be especially careful. Take more photos.

Beware of rats.

[SteveD]

Here's the tool, called a Macgills forcep.

I've read before that painting the inside of the bucket in white is an improvement when looking for colours.

[Deleted User 62]

Hey Ron, scary isn't it! I've done a couple and here's what works for me. On a piece of paper draw a basic diagram of the bucket and it's main components, flasher, top switch, fuse block etc. Then, starting with the wires closest to you; headlight socket, fuse block, connector board, etc. remove and make a note on the drawing of the connector number (see you manual) or description; "red, ignition switch" As you go deeper, you will disconnecting the wires to the handlebar switches and instruments. Note how their harnesses lay around the back of the bucket. Finally, pull the tach and speedo cables and remove the speedo. Then comes the ignition switch. There are four tabs which must be bent straight in order to pull the switch board down. Once off, you'll see four more tabs holding the switch cover. Paint at will... It helps if you have a color wiring diagram, in order to see what they mean and look where they go. It's a puzzle worth learning! Assembly is the reverse. You were taking notes, remember?

[Ron Baker]

Thanks for the help guys. I work in a hospital electronics dept and have never seen forceps like those. May have to see if I can find some.
Thanks

[Ron Baker]

Well, got er done. Tim, Thanks for the tip of making a diagram, sure made it easier coming apart. I'll clean up a few wires, while it's out being painted. I'm taking everything except the frame to the local votech to have done. The instructor there is very meticulous with his students. Looking forward to getting it back.

[SteveD]

Thanks for the help guys. I work in a hospital electronics dept and have never seen forceps like those. May have to see if I can find some.
Thanks

Commonly used for endotracheal intubation Ron. ICU, ER or op theatre's will have them. With a bit of luck, they'll be single use only and disposable. If you get one, soak it in bleach for a while!

[chasbmw]

It helps to paint the inside of the bucket white.

Really take a note of how the different wires are bent around the inside of the headlamp. The main wiring to the circuit board is easy as it is Colour coded, but it's easy to get the wiring into switches and relays mixed up.