Getting ready to have my headlight powder coated but ran into a small snag. Seems the back shell comes already assembled with the grommet and wiring running through the back of it.

The hole through the back shell is not going to be big enough to pull either of the ends through so I am thinking I'll just snip the wires pull them out then solder them together later.

Just wanted to put this out there in case anyone has totally disassembled a headlight before and maybe has something I am over looking that would not require me to cut wires?

Anyway, I'll get some pics posted when it is done and all back together.

 

You don't "have" to cut the wires. If you have a copy of the service manual, and if you don't I highly recommend that you get one. It shows how to disassemble the plug. Once you take the pins out of the plug they slip through the grommet very easily.

 

I do but I didn't see anything about removing the pins from the plug? I'll look again tonight. Maybe it is in a different section than the headlight?

Thanks,

Rich