Couple questions as I prepare to assemble the headlight area:

Are the headlight shroud bolts 5/16 x 24? I've tried but doesn't go all the way in. Might need to chase the threads.

How do the spot lamps work? Are they wired in the head lamp circuit?

Thanks
Nick

 

Without the passing lamp bracket it is 5/16-24 x 9/16

With the passing lamp bracket the top is 5/16-24 x 1-1/4 and the bottom bolt is 5/16-24 x 3/4. Each bolt uses a washer (5/16 x 11/16 x 3/16). There is also a spacer for the top of the bracket that goes between the bracket and the shroud (#58102-49); the bottom uses a 5/16 x 15/16 x3/16 washer between the bracket and the shroud.

If you are having problems with the top bolt bottoming out too soon it usually means you do not have the fork tube top plug on the flat side facing your bolt.

Re: your passing lamps. If you are using the stock terminal block that is mounted, you have an unsued terminal at #11 on the block (it has four connecting points). Route the left and right passing lamp wires (uses a 1/8 slot female spade connector) to two of them. Connect a third wire from that post to one side of your passing lamp switch. From the other side of the switch route and connect a wire that ties in with the low beam wire on your headlight.

If you do not have the stock terminal block for your year model you can wire the passing lamp wires directly to one side of your switch and route the other to the low beam wire. Functions the same way.

If wired correctly the passing lamps will not come on until you turn the passing lamp switch to the on position and will automatically turn off when you switch from low beam to high beam on your handlebar switch.

 

Thanks Panz. I have factory terminal block. Regarding the Spot lamps - I have two switches. One is emergency switch which I got wired up. The other has two poles, each with a blue wire. One blue wire goes to the 3 section of the block where the orange wires are and the other goes to what looks like section 8 which is to the left of the red wires (the lines and numbers on the terminal block are really faded). Is this the switch?

 

I got the lamps wired to the second switch.

I checked the turn signal bulbs and they are dual-filament and there are 2 wires + ground so I'm assuming that they are running lights also?

 

we run a separate wire for the spots as an old machine does crazy things sometimes and having the spots at night on its own line seems like a smart move

 

It urns out I had a broken bolt in one of the mounting holes so I had to extricate that then chase the rest of the other holes.

I also discovered that the spot lamp I picked up locally didn't fit - the frame was too narrow. It must be for a later bike. I found one on ebay that I will move the lights over to and mount that.

Thanks for all the help. Almost ready to register and ride.
Nick

 

How timely! I'm hooking up spots, soon. John, you wire them to a hot so you can turn them off and on any time, independent of brights? That's what i wanted to do.

 

it gives you control separate from the HL switch in case of an outage at the switch at 2 am