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Heads Above Stock Lighting

Ride Safer, Ride Faster
By Toph Bocchiaro
Photography by Toph Bocchiaro
Upgrading A Stock Headlight
1. Headwinds headlight peeking... 
   
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Upgrading A Stock Headlight
1. Headwinds headlight peeking out from beneath the Sporty's eyebrow.
Upgrading A Stock Headlight
2. Here's the top-mount,... 
   
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Upgrading A Stock Headlight
2. Here's the top-mount, 5-3/4-inch Concours Bullet headlight bucket, Cibie e-code headlamp, H-4 halogen bulb (60/55W), and protective boot.
Upgrading A Stock Headlight
3. Inside the stock 20+ year-old... 
   
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Upgrading A Stock Headlight
3. Inside the stock 20+ year-old headlight bucket lurks a bee's nest of wires and connectors. Since I was going with a new Wire Plus wiring harness all of these wires but three will be pitched into the dumpster.
Upgrading A Stock Headlight
4. After unplugging the old... 
   
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Upgrading A Stock Headlight
4. After unplugging the old headlamp, the plug on top of the eyebrow (headlamp bracket) was pried off with a knife.
Upgrading A Stock Headlight
5. Under the plug is the... 
   
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Upgrading A Stock Headlight
5. Under the plug is the single mounting nut for the headlamp assembly. After removing the nut, the old headlamp was thrown in the recycle bin.
Upgrading A Stock Headlight
6. The simple mounting hardware... 
   
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Upgrading A Stock Headlight
6. The simple mounting hardware allows the headlight to be moved and tilted in the eyebrow groove by using a tapered washer.
Upgrading A Stock Headlight
7. This plastic H-4 pigtail... 
   
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Upgrading A Stock Headlight
7. This plastic H-4 pigtail (bulb-socket) consists of three wires terminating in spade connectors that match the P43t base of the bulb. Yellow is low beam, white is for the high, and black to ground.
Upgrading A Stock Headlight
8. The high and low beam... 
   
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Upgrading A Stock Headlight
8. The high and low beam wires from the new harness match the H-D color scheme. A piece of black wire-conduit was used for a cleaner installation and protection.
Upgrading A Stock Headlight
9. This bucket has one hole... 
   
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Upgrading A Stock Headlight
9. This bucket has one hole with an included grommet for the wires to pass through. The diameter of the conduit was a nice fit in the grommet and will help keep out water.
Upgrading A Stock Headlight
10. Once the wires were pushed... 
   
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Upgrading A Stock Headlight
10. Once the wires were pushed through, the threaded headlight bucket stud (on top of the headlight) was lined up with the hole in the eyebrow, followed by the washers and nut, and snugged up.
Upgrading A Stock Headlight
11. After stripping approximately... 
   
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Upgrading A Stock Headlight
11. After stripping approximately 1/4-inch of insulation off the wires, they were tied together and soldered. Note the short piece of shrink tubing installed (arrow). You must put the shrink on before tying the wires together.
Upgrading A Stock Headlight
12. After soldering the wires... 
   
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Upgrading A Stock Headlight
12. After soldering the wires the shrink tubing was heated with a mini-torch. Heatguns are easier to work with and safer, but I like fire. The shrinkable tubing contracts to form a tight seal around the joined wires. It's extra protection while looking sano and professional.

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