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Replacing Plastic Headlight Bucket with Metal version

Discussion in 'Norton Motorcycles (Modern)' started by SgtUSAF80, Dec 10, 2017.

  1. SgtUSAF80

    SgtUSAF80

    Joined:
    Nov 21, 2017
    I am in the process of replacing the headlight bucket on my 2013 961 SE from plastic to metal. What a rat's nest of wires and connectors in the bucket! This won't be a quick, couple minute job. It looks like the multiple connectors will have to come apart to get the cables and wiring harnesses out through the hole in the old bucket and back into the new one. I can figure that out. What has me a little stumped is the small 5W bulb and its wiring. The new headlight has this 5W bulb already installed with a BROWN and a BLACK wire (each about 7"/18cm) coming out of it. The old headlight has BLUE and YELLOW wires coming from this 5W bulb going to 2 different connectors. Are there any Electrical Einsteins out there who can tell me what is what so that I can make the correct connections?
     
    Last edited: Dec 10, 2017
  2. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    I replaced mine and there were zero challenges. Look at my light bulb manual. Maybe the colors are in it. I don’t remember and I’m on my phone. Let us know how you make out.
     
  3. pingu-nz

    pingu-nz

    Joined:
    Jun 24, 2011
    Hi
    I have just replaced my headlight for a metal bucket
    Take plenty of photos of the connections ,so you don't mix them up
    Take special note of the clutch switch and front brake switch connectors ,if you mix them up bike won't run .
    It's not that hard of a job just fiddly.
    Good luck
     
  4. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    Page 10 of my manual. No need to unplug all the wires. Hope this helps.
     
    Voodooo likes this.
  5. nopdog

    nopdog VIP MEMBER

    Joined:
    Apr 24, 2017
    Any chance you can give me the heads up on where to get a chrome bucket replacement.
     
  6. SgtUSAF80

    SgtUSAF80

    Joined:
    Nov 21, 2017
    Thanks Richard. Just pull them all nice and straight and feed them through. Got it. Any idea about the wires from the 5W "parking" bulb, the blue & yellow ones? The new 5W bulb and housing has brown & black wires. I attempted to use the original setup, but the rubber housing surrounding the bulb is smaller in diameter than the new one. The original setup just flops around in the new headlight. So....I need to use the new bulb and rubber housing. Black is usually ground..attach that to the blue or yellow wire or does it not make any difference? I'm fairly good at making most things work but anything electrical easily overwhelms what brain cells I have left.
    Thank you again for your assistance!
     
  7. SgtUSAF80

    SgtUSAF80

    Joined:
    Nov 21, 2017
    The headlight is installed and it looks better than the plastic one...sort of. The opening for the wires/harnesses on the metal one is on the bottom of the shell, so you will end up seeing a lot more of those wires/harnesses than with the plastic headlight which has the opening on the back. The plastic headlight is nicer in that respect. You will also need to cut the old wires leading from the "parking light" bulb housing and splice in the new one from the metal bucket. The rubber housings are not interchangeable. The metal headlight certainly has a more classic look, but I am not 100% sure, at this time, if I would make the switch again if given the choice. My 961 is a USA SE built in May 2014.
     
    Last edited: Dec 13, 2017
  8. Britfan60

    Britfan60

    Joined:
    Jan 5, 2014
    Quite a bit of the harness is exposed? Hopefully all the connections are protected, no? I'm in a salt water environment.
     
  9. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    \[​IMG]
    Here's mine.
     
  10. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    Lower shot
    [​IMG]
     
  11. SgtUSAF80

    SgtUSAF80

    Joined:
    Nov 21, 2017
    Is yours part # N06700060 ? The edge of the opening for the wires on the one I received is only approx. 1 1/2" from the trim ring! A shot of my bike from the same angle as yours would clearly show a whole pile of wires/connectors/harnesses outside of the opening in the bucket.
     
  12. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    I don’t actually know the part number. I’ll try to find out for you. I got it spring 2016
     
  13. Voodooo

    Voodooo VIP MEMBER

    Joined:
    Aug 10, 2016
    Either reuse the original bulb and wiring or attach the new wiring. “I recommend reusing the original wiring” and just keep the new pig tail Incase you ever need it in the future.
     
  14. BritTwit

    BritTwit VIP MEMBER

    Joined:
    Aug 25, 2009
    So this means that you don't need to do any cutting/splicing of the existing harness to install the new shell/headlight assembly?
     
  15. SgtUSAF80

    SgtUSAF80

    Joined:
    Nov 21, 2017
    Voodoo,
    The original rubber housing holding the 5w bulb does not fit in the new headlight. It is a smaller diameter and slightly different construction than the new one that comes with the metal headlight bucket. If you try and place it in there it will just flop around. That is the reason for splicing the new bulb/housing to the existing wiring.
     
  16. 961 S

    961 S VIP MEMBER

    Joined:
    Jan 7, 2015
    Hi Rich,
    I would like to upgrade my plastic headlight to metal. Do you have the part numbers for the assembly? Does the new headlight include the lens and rim clamp?
    Bill
     
  17. richard-7

    richard-7

    Joined:
    Feb 24, 2014

    Hi Bill. I don’t know the pn off hand. I just asked Peter for the latest (2017 at the time) bucket.
     
  18. 961 S

    961 S VIP MEMBER

    Joined:
    Jan 7, 2015
    Hi Richard,
    Since my inquire on the metal headlight, I contacted Norton UK and was able to order a chrome bucket. I also found a peak (with Norton Pressed on it) on the net. I am all about retro and I like what I have done with my headlight. IMG_1560.jpg
     
    thesixthelephant and Britfan60 like this.

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