How to turn an 04 Sportster headlamp off (might work for others, too)

[Gib]

Phew - got mine done at last

Tell you what though, its ok to theorise, but when you have the snippers ready to cut that first wire on your pride and joy its a bit like those films where a guy's defusing a second world war bomb. Very tense!

Anyway, this is how I did it (2004 Sportster Custom). If you want to have a go, feel free, but I accept no responsibility for anything that goes wrong, fires, explosions, acts of war or subsequent prosecutions. Or anything else for that matter. It worked for me, though.

General: (please don't be offended if I'm teaching granny how to suck eggs, I've no way of knowing who might read this, so I'm going for the lowest common denominator!!):
a. The headlamp is fed off the lighting circuit (blue).

b. The front position and rear lamps are fed off the accessory circuit (orange/white).

c. All bullet connectors and new bits of wire are 15 amp.

d. Disconnect battery before starting, reconnect after.

e. Whenever you snip a wire make sure you do it far enough away from the block to leave you room to work (and fit a bullet connector to both of the cut ends).

f. Make sure there are no live wire ends anywhere that might earth on anything - always properly blank off any that no longer go anywhere.

g. Take the seat and fuel tank off.

Fitting the new switch:
1. Fit the switch (I did it on the left) HD part no 71718-02 (switch), 70248-02 (switch housing) to the handlebars and feed the wires down to near the connector block (number 24 in wiring diagram) under the fuel tank. Block 24 is a 6 way Deutch type that goes to the l/h handlebar switches. Fit new male bullet connectors to each switch wire.

Wiring to the headlamp:
2. Unfasten the front bit of block 24 (to make access easier) and snip the blue wire coming out of it. Fit new male bullet connectors to each cut end.

3. Connect the blue wire coming out of block 24 to the plain gray switch wire using a new 2 way female connector.

4. Connect the blue wire going to the handlebar switches to the gray/white switch wire using a new 4 way female connector.

Wiring to the front position lamp:
5. Find the connector block that goes to the headlamp (number 38 in the wiring diagram) which is next to block 24. Block 38 is a 4 way multilock type with orange/white, white, yellow and black wires coming out of it. Snip the orange/white wire coming out of the front of the block (to the front position lamp) and fit new male bullet connectors to each cut end.

6. Connect the orange/white wire going to the front position lamp to the new 4 way female connector from step 4 above.

7. Connect the orange/white wire coming out of the block into a new spare (or blank) 2 way female connector.

Wiring to the rear lamp:
8. Under the seat, unfasten the Ignition Control Module (ICM) and move aside to get access to block 7. Block 7 is a 6 way multilock type that feeds the rear lamps. Snip the orange/white wire (to the rear position lamp) and fit new male bullet connectors to each cut end.

9. Run a new length of blue (15 amp) wire from the new 4 way female connector (from step 4 above) to block 7 under the seat. Fit new male bullet connectors to each end. Connect one end of the blue wire into the 4 way female connector from step 4 and the other end to the orange/white wire going to the rear lamp.

10. Connect the orange/white wire coming out of block 7 into a new spare (blank) female connector.

Finishing off:
11. Zip tie it all up so its nice and neat, liberally spray all new connectors with WD40, replace the ICM, tank and seat and Bob's your uncle.

Good luck!

[Battersea]

Just as a matter of interest why would anyone want to turn the headlamp off

Like Battersea, why do you want the light off, surely its safer on!.

[the_monster]

I switch my lowrider (05) off and tke the key out - hey presto no headlight

I did take to using a rally bulb in my headlight which meant that on coming traffic was blinded, anyone in front was blinded, I had a clear road because of aforementioned incidents and could see for miles and miles and miles - wtch out now;) The flip side is no one could say they couldn't see me !!!!!! nowadays I use loud pipes as they lives especialy mine

When the battery get older it good to have the option of no headlight at start-up, more juice going to the starter.

[Gib]

I did it because I want the choice - simple as that. The idea that having my headlamp on will make me safer under all circumstances is simplistic, to say the least. I'd rather assume that drivers won't see me and ride accordingly, as I've done for the past 35 years.

If you want to have your lights on all the time, well that's ok for you - I wouldn't dream of criticising your choice. But if, like me, you prefer to have a choice, I hope my note is useful. Besides, fitting a switch doesn't mean you can't switch them on again.

If you want to read a proper rant on the subject have a read of my letter in the next issue of the Road, MAG's magazine. At £20 a year, membership is a bargain.

[the_monster]

Originally Posted by harleyhog

When the battery get older it good to have the option of no headlight at start-up, more juice going to the starter.

get a new battery - it makes for easier starting

[Spen]

Originally Posted by the_monster

get a new battery - it makes for easier starting

I thought your Lambretta was magnito with a kickstart

[Yellow_peril]

Originally Posted by Spen

I thought your Lambretta was magnito with a kickstart

But would he know what to do with a kickstart, Spen?

Mucho respect, mate!