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Discussion Starter #1 (Edited)
hi all

all the parts that i've ordered have finally dribbled in and today i began the resurrection process of my bonneville.

but i came across a few, small snags...

replacing the headlight brackets: my approach to get to the brackets, since i don't have a jack, was to remove the yoke from the top. i loosened the top nut from the steering stem and one of the fork bolts. i had never done this before. when i finally unscrewed it completely, the the metal spacer tube in there sprung out at me like a jack-in-the-box and scared the crap outta me. sweatmachine didn't mention that part!!

only then did i realize that there was some giant-sized allen wrench that i'd need to loosen the top yoke clamp bolts. i did come prepared with allen wrenches, but didn't have any in THAT size. anyone know what size this is??

here's a pic - http://s25.photobucket.com/albums/c100/metasac/smashed bonneville/?action=view&current=hpguytestingforcomm014.jpg

also - while i'm at it, what size is that steering stem bolt? i sort of, uhhhh... used an adjustable wrench to loosen it (*cringe*) i'd like to use the correct tool next session.

i also have to replace my turning signals. can't help but notice that the male and female bits aren't agreeing with each other. what's the smartest/easiest thing to do here? i do have a good soldering iron and some skill. should i go buy some new connectors and do some soldering? what kind? any other ideas? HELL - i don't know - maybe those aren't even the turning signal plugs! are they? seemed like the only things it would make sense to plug them into.

see some pics of the turning signal issue here:
http://s25.photobucket.com/albums/c100/metasac/smashed bonneville/?action=view&current=hpguytestingforcomm013.jpg

http://s25.photobucket.com/albums/c100/metasac/smashed bonneville/?action=view&current=hpguytestingforcomm012.jpg

http://s25.photobucket.com/albums/c100/metasac/smashed bonneville/?action=view&current=hpguytestingforcomm010.jpg

i also bought this aftermarket headlight shell: http://mcctriumph.com/images/IMG_0330.JPG

i am TERRIFIED of how i'm going to handle the wiring mess. the hole on this shell and the shell itself is a bit smaller than on the stock shell. trying to fit any one of the other plugs - the ignition, the reg/rectifier, etc - is like watching a chihuahua trying to give birth to a great dane! any links to folks who've done a good tuck-away job with their wires? i just don't see how it's gonna be possible for me to run wires in and then OUT of this shell!

lastly, i finally swapped out my handlebars. i don't know what i had before, since i bought the bike used, but i never liked them. now i'm rockin the flanders wide clubmans and they feel much more comfortable, natural, and seem to have just the right amount of pullback for a slightly more upright position.

any advice and thoughts would be much appreciated, as always. can't WAIT to get back on the road again!
 

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I'd just cut the connectors on the signals and hardwire them with some heat shrinks. It's scary using the adjustable wrench on the head bolts, but much cheaper than a new socket.
 

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I think the clamp bolts are 6mm Allen. Get yourself a set of 3/8"-drive metric Allen bits for your ratchet. You're going to need them anyway to properly torque these bolts (and others) with your 3/8" drive torque wrench.

I don't know the size of the steering stem bolt, but you can measure it. A cheap sliding caliper works well for this. If you buy a socket for it, get a 6-point socket, which you'll find with the impact sockets (the regular ones will be 12-point). It'll do less cosmetic damage to the bolt.
 

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Discussion Starter #4
i came with 6mm allen - but they were about 2 or 3 sizes too small! good idea about the allen bits, though. i'll take your advice on that and the 6-point impact socket. thanks!

I think the clamp bolts are 6mm Allen. Get yourself a set of 3/8"-drive metric Allen bits for your ratchet. You're going to need them anyway to properly torque these bolts (and others) with your 3/8" drive torque wrench.

I don't know the size of the steering stem bolt, but you can measure it. A cheap sliding caliper works well for this. If you buy a socket for it, get a 6-point socket, which you'll find with the impact sockets (the regular ones will be 12-point). It'll do less cosmetic damage to the bolt.
 
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