Breakout conversion to 7" headlight

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Mar 14, 2016 | 01:57 PM

#11

burnsy87

Tourer

Joined: Sep 2013

Posts: 390

Likes: 1

From: Omaha

Quick picture, just got it done with Furry's guidance. Thanks again man

May 27, 2016 | 07:59 PM

#12

Boogie man

Stage II

Joined: May 2016

Posts: 2

Likes: 0

From: Chicago

Harness question

Quote:

Originally Posted by FurryOne

Here's a few pictures to show a conversion to a 7" chrome headlight bucket and LED headlight for the Breakout. The bucket is an eBay special at $70 shipped...

http://www.ebay.com/itm/361034589737
Do

It's pretty much a direct replacement with a few caveats...

1. The bolt for the block that mounts it to the triple tree is NC Fine, so you'll need to purchase one - I think I used a 5/16x1.75 NCFine. (The original HD bolt is course thread)

2. The bucket comes with a harness, but it's easier to use the one from the original 5" bucket. You can release the contacts in the connector, then pull the wires back out and use the same rubber seal on the new 7" bucket. I cut the rubber on mine because I have an extra wire for the garage door opener sense wire to the Hi-beam lead.

3. If, like me, you have a windshield, you'll have to re-radius the opening for the new bucket. (Always fun cutting a windshield)

Here's a few photos.

Do you swap out the harness at the end that connects to the bike or the end that connects to the headlight itself?

May 29, 2016 | 08:56 AM

#13

FurryOne

Thread Starter

Road Master

Joined: Jun 2013

Posts: 953

Likes: 127

From: Rome, NY

Quote:

Originally Posted by Boogie man

Do you swap out the harness at the end that connects to the bike or the end that connects to the headlight itself?

I kept the original harness/connector. I just disconnected the battery, then using 2 jeweler's screwdrivers released the contacts in the H4 headlight connector and pulled the harness out the back of the original bucket. Most new 7" buckets come with a wiring harness already installed. I removed that one and fished the old harness into the new bucket and slipped the contacts back into the H4 connector. Releasing the contacts in the H4 connector takes some skill as it's not obvious at first how the locking mechanism works, but they will slip right out the back once you get it figured out.

Here's a new set of drawings showing the plastic "locks" in the H4 connector. It takes 2 screwdrivers because there's a plastic piece between the 2 locking tabs.

NOTE: If you're looking at the 7" Daymaker or the EVO2, save your money and go for the new Speaker 8790 Adaptive 7" LED headlight. Yeah it's expensive, but what's your A$$ worth to you?

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