Headlight/Horn Assembly

[LakeOber]

Hello,
When I purchased my 1980 Special from the PO it had the Windjammer (i believe) fairing installed. He had cut down the windscreen, so it really didn't do a whole lot. However, he also included all of the original headlight parts so that the fairing could be removed. I personally think I would like the look of the bike more without the fairing, so this weekend I took it all off (I'm sure I will get all sorts of crap from you guys )

Anyways, I am currently in the process of reinstalling all of the original headlight parts. In looking at some parts diagrams, I am confused at how to install the horns back on the frame. I have all of the parts in a big bag, so I have to try and figure out where things go using trial and error. Would anyone possibly be able to help me out with a (or a few) close-up pictures of the horn mounts, and the headlight assembly? I think I have the headlight assembled properly but there is a nest of wires behind it that I need to figure out something to do with.

Thanks!

[DiverRay]

The horns mount on a flat steel bar that should bolt up under the front of the tank. Should be two mount points on the front frame down tubes.
The wires ALL fit INSIDE the headlight bucket! Yeah, I know, but that is what Yamaha and everyone else was doing at the time. There should be rubber grommets around the holes in the back of the bucket. You will need to feed the connectors one at a time through the holes. The gauge and handlebar wires go through the top holes, and the main wires go through the larger holes in the bottom part of the bucket. As you connect them, keep them to the back and distribute them around the inside of the bucket so the headlamp will fit.

[LakeOber]

The horns mount on a flat steel bar that should bolt up under the front of the tank. Should be two mount points on the front frame down tubes.
The wires ALL fit INSIDE the headlight bucket! Yeah, I know, but that is what Yamaha and everyone else was doing at the time. There should be rubber grommets around the holes in the back of the bucket. You will need to feed the connectors one at a time through the holes. The gauge and handlebar wires go through the top holes, and the main wires go through the larger holes in the bottom part of the bucket. As you connect them, keep them to the back and distribute them around the inside of the bucket so the headlamp will fit.

That makes a bit more sense with the horn. I had a metal piece I couldn't figure out what it was for. It looks like this:


Is this the piece that mounts to the frame, and then the horn to it?

And thanks for the help on the wiring, I wouldn't have guessed it all went in the headlight bucket, but now that you mention it, it makes more sense. I was wondering where that was all going to go. Thanks!

[DiverRay]

Yes, that looks like the horn mount. One horn should be on each side of the tank, just in front and below. The part number tag is probably hiding the mount holes. IIRC the weld nuts go to the back of the bike, but I'm not 100% sure.

[Ranger_xs1100]

Hello,
Would anyone possibly be able to help me out with a (or a few) close-up pictures of the horn mounts,
Thanks!

[LakeOber]

AWESOME! Exactly what I needed. Thank you!

[LakeOber]

Thanks again Ranger for the pics of the horn assembly. I was able to get it all back on correctly. The last thing I have to do is put the bucket on and route the wires (I have been delayed by the 16" of snow we got here in PA). Does anyone happen to have close up pictures of the wires in the headlight bucket? I would really like to see some for reference when putting it all back in there.

Thanks!

[dpotter58]

The plugs only go in the correct ends. They are all different with the exception of the turn signal wires. Figure out which signal goes where by turning it in then plugging into the open plugs. The wires on the signal stems go into the black, they are grounds.

[LakeOber]

Ok, I have it together for the most part. I only ran into a few issues:

1. There is a red wire that has a barrel connector. Not sure what this goes to.
2. There is a dark blue wire with a barrel connector (the one in the picture with duct tape on it). Not sure what this goes to. It says in the install manual for the fairing that this is for the running lights.
3. There is a light brown wire with a double barrel connector on it. I have one light brown wire to plug into it, but not two. Is there another one that should go in there? I looked at the wiring diagram but was not able to locate these wires. There is a lot on there to look at

Can anyone please provide some clarification on the above wires? Thanks!

[DiverRay]

If everything works, your good. Yamaha had "extra" wires in all the big bikes for fairing mounting, etc. I'm used to the Standard model, but they are all about the same.

[Ranger_xs1100]

headlight

LakeOber, I think you got it! good job....
I'm posting this picture just so you have confirmation.
Notice in my picture that the double blue wire is not connected to anything and neither is the single red wire, and the double barrel does only have one brown wire going to it.

[3Phase]

Ok, I have it together for the most part. I only ran into a few issues:

1. There is a red wire that has a barrel connector. Not sure what this goes to.

Red wire is 30 Amp Main unswitched power straight off the battery and before the Ignition Switch. That Red wire has +12V all the time unless the Main fuse pops. Be careful with it and use an appropriate fuse for anything you connect like a radio or GPS.

2. There is a dark blue wire with a barrel connector (the one in the picture with duct tape on it). Not sure what this goes to. It says in the install manual for the fairing that this is for the running lights.

Blue wire is Auxiliary Lighting. It's on the 10 Amp fuse from the Head circuit and is 'off' until the engine starts and the lighting turns on.

3. There is a light brown wire with a double barrel connector on it. I have one light brown wire to plug into it, but not two. Is there another one that should go in there? I looked at the wiring diagram but was not able to locate these wires. There is a lot on there to look at

Brown wire with the double-barrel connector is switched Accessory power. It's on the 20 Amp Sig circuit and is hot when the Ignition Switch is turned on.

The single Brown wire in the connector is +12V for the front brake light switch. The Green/Yellow wire runs from the switch back to the rear brake light switch, then on back to the two Brake light bulbs.

Can anyone please provide some clarification on the above wires? Thanks!

You're welcome! Nice pictures too!

[LakeOber]

You guys are awesome! Exactly what I needed. Thanks!

[DeanR]

Sure is clean inside that headlight bucket Mr. Ober.

Way to help him out everyone, with great info. But that's to be expected here, isn't it.