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Discussion Starter #1
In the course of tossing my '02 down the freeway on a lark, the plastic headlamp bucket shattered. Got a new one, trying to put it all back together, and there's more wire and connector than there is space.

Anyone got pics of what it's supposed to look like, or even just a writeup on how to do it? I am screamingly frustrated, feels like I've tried eleventy-hundred different ways and times and it just won't go!
 

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In the course of tossing my '02 down the freeway on a lark, the plastic headlamp bucket shattered. Got a new one, trying to put it all back together, and there's more wire and connector than there is space.

Anyone got pics of what it's supposed to look like, or even just a writeup on how to do it? I am screamingly frustrated, feels like I've tried eleventy-hundred different ways and times and it just won't go!
First order of business......take a deep breath, a beer or whatever will let you get perspective back.

I will pull the headlight off and take a picture for you. I will try to have it up in just a few minutes....check back after the beer or ???

YOU WILL WIN.......
 

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That's a class act! What other forum can you find such great members?

Icylic...are you having problems getting all the wire through the holes in the bucket, or just having trouble getting the light back in once everything is connected?
First order of business......take a deep breath, a beer or whatever will let you get perspective back.

I will pull the headlight off and take a picture for you. I will try to have it up in just a few minutes....check back after the beer or ???

YOU WILL WIN.......
 

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Discussion Starter #4 (Edited)
No, I managed to get all the wires through the very tiny hole in the bucket, but after reconnecting all the little plugs (So many colors! Whee!) it's just this sort of... tangled mess. And the picture in the factory service manual is a complete joke. Feh.

So, basically, the issue is that I don't know which wires / plugs to put on which side of the bucket, or through which wire clip to put which bundle, to hold it all in place so that the headlight unit will fit in place.

I've got to admit, I've been strongly considering just doing something aftermarket, because I'm not sure if the money it would cost would be worse than the ulcer I'm going to give myself over this. ;)

I will pull the headlight off and take a picture for you. I will try to have it up in just a few minutes.
That's very swank of you, scawein. I sure do appreciate it. :)

*does yoga or some **** to get all zen*

------

What was weird to me is, I searched, and couldn't find any other threads about this. Either everyone else has found this much easier than I am, or I suck at searching.
 

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Here's an image from the Service Manual. Though it's in b&w, it may be of some help while waiting for the photo from Scawein.


 

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There you go. You just have to get them to lie on the outside (inner) of the bucket. Once routed, most of them should fit in the little hold down clips on each side.

This would also be a good time to put dielectric grease on your connectors while it is open.

Yes some of the connectors look different then stock. I changed some when I internally wired my handlebars.....

Sorry it took a few, dang gmail took a while to pass them to me.

Holler if you need more help.
 

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Discussion Starter #8
Ok, those are great pics. I'll give it another shot and see what it gets me. Thanks very much. Hopefully yours goes right back together, I'll feel like a jerk if you took yours apart to show me how to fix it and then you can't rebuild yours! :D
 

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Ok, those are great pics. I'll give it another shot and see what it gets me. Thanks very much. Hopefully yours goes right back together, I'll feel like a jerk if you took yours apart to show me how to fix it and then you can't rebuild yours! :D
No problem, it comes on and off very easy as long as the wires are dressed well. The main idea is to create a bowl shape with all the wires so they hug the outer areas of the bucket. If you look for a bit, you should see the natural way they want to lie in there since you are just putting them back.

Feel free to check in as you need to.
 

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There you go. You just have to get them to lie on the outside (inner) of the bucket. Once routed, most of them should fit in the little hold down clips on each side.
These are first class pictures Scawein, well done for helping out :cool:
I wish mine looked as neat in there as yours.
I'll be having a copy of them for when I get the nerve to undo the bolts and let the lot pour out :eek:


Gav.
 

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These are first class pictures Scawein, well done for helping out :cool:
I wish mine looked as neat in there as yours.
I'll be having a copy of them for when I get the nerve to undo the bolts and let the lot pour out :eek:


Gav.
DITTO scawein - real class posting and pics.....just the man needed in a crisis

ps - i've also stolen the pics....lol:D
 

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I was thinking of taking my headlight bucket off to paint (as part of a midnight conversion) but seeing all that I got scared.
 

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Discussion Starter #13
If you look for a bit, you should see the natural way they want to lie in there since you are just putting them back.

Well... you see, it's also been *cough cough mumble* five years since I had my wreck and I'm just now getting to this point, so the wires have had some time to relax...

I got home from work a bit ago going to head out and give it a shot in a minute, I'll post back and let y'all know how it went. :)
 

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I was thinking of taking my headlight bucket off to paint (as part of a midnight conversion) but seeing all that I got scared.
Easy stuff, especially if you look at the natural lie of it. Like I mentioned earlier in the thread, always good to put some dielectric grease on your connections so you ultimately need to be in there anyway.

For a mod?????? no problem (paint that thing....lmao)
 

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Discussion Starter #16
******* HUZZAH, DUDE!

It's back together. I'd take a pic, but my phone is put of batteries. I'll take one later. Thanks a bunch, man, I totally owe you a beer. I was honestly so far frustrated I was just going to make a new headlight mount rather than deal with that one... :D
 

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******* HUZZAH, DUDE!

It's back together. I'd take a pic, but my phone is put of batteries. I'll take one later. Thanks a bunch, man, I totally owe you a beer. I was honestly so far frustrated I was just going to make a new headlight mount rather than deal with that one... :D
YOU WIN! knew you would....glad we could help!
 

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Discussion Starter #19
Hunh. That picture is pretty good. Too bad there's nothing like it in the '02 manual. :(

It honestly hadn't occurred to me until this very moment that they might have improved the documentation alongside the machine itself, over the years. Doh.
 
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