Topic: Trying to put a small headlight on my cb500 1972, What do I do with the wiring!

[Maximiliaanvk]

 
So I wanted to put a small black light on the front of my cb 500f 1972. Im cleaning up the front end and putting clip ons on it.
I want to maintain all the functions that the electronics currently do and I was trying to keep the original switches on the handle bars for indicators starter etc. because I like the old look of them. And $... which I'm aware means ill need to drill some holes in the handle bars to run the cables through them.   


So I opened up that headlamp and yea, the wiring is a complete mess. 
Short of completely starting the wiring over from scratch, (which I don't know if i have time to) What can I do with this wiring?

I wanted the light to be bottom mounted. Which is why I can't keep the original bucket. Plus I wanted it to be smaller.

WELCOMING ALL SUGGESTIONS! Pictures help!

Thanks.
M.

[lucky]

You can do what the manufacturers have done on other bikes. Hide the wires in a black plastic box.
I have also hidden them in a black fuzzy pouch made from a seat belt shoulder protector. You can get different colors too. to match the frame or gas tank.

[Maximiliaanvk]

Hmm ok,

I mean i'd rather not drop $400 on it yet. Also id still have to find a place to put that box, and it seems like it wouldn't look as clean to just leave it there. So if i was going to drop $400 i'd go through the effort of relocating it too. But its pretty bad ass.

I have the coloured wire diagrams. What do you mean by the black and white ones? this one I have seems to cover all of the wires?

My main reserve when rewiring the whole bike is last time I did that on my BMWr100rs a year ago I started an electrical fire and burnt out all the cables haha I know rookie moves but I was a rookie, so live and learn. Rewired the entire bike. Now i'm wire phobic.

The Pouch could be a cool idea, just zip it to the frame in a pouch.

I was also just thinking of maybe going a little bigger.
 http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-electronic-lighting-parts-retro-satin-black-mini-bates-brass-headlight-67-7727.html

but I don't think this will fit the wiring either. :/

Im gonna try see what a pouch would look like as its the path of least resistance for right now. How did you construct the bag? It need to be quite water tight.

[Maximiliaanvk]

I Won't be having side covers.

And for that id have to rewire, because obviously that bunch of wiring wont reach how it is now?

[martin99]

calj737 is right. You can't expect to do a mod like this without some re-wiring. You may gain some more 'room' to stash your wires by unwrapping the insulation to where the main loom just enters the back of the headlight bowl - it will release some of the stiffness and allow you to unravel the wires to tuck them around the back and sides. Changing any block connectors in there to bullets will also reduce bulk and give you a bit more choice in laying the wires out around the bowl. Doing it this way takes up less room but whether or not it will be enough to be able to keep all the original wires in your new headlight? You'll just have to try.

[Maximiliaanvk]

Yea I just went for it.
rewiring the it all, the control wires and dash wires seem to be long enough to reach under the tank by the starter cable. Might try changing the connectors out and put them all down there

I will let you know if I succeed! But from what i've done so far, it looks like it will work.

[Maximiliaanvk]

Does anyone have a recommendation for a bracket to mount the light?
Was going to fabricate something simple, But It would be nice if there was a piece for this?

The bottom triple tree is stock.

[alacrity]

Actually he wouldn't be totally "toast," as I have a perfectly good used lower triple for a cb500 in my garage.. That will be sold eventually