Triumph T100 - British Customs Headlight Ears and BAAK Shallow Headlight Install

To install the British Customs headlight ears to the 2019 Triumph Bonneville T100 Black, it was necessary to replace the original Triumph OEM headlight bowl with an aftermarket BAAK shallow headlight bowl.

The British Customs headlight ears are shorter than the Triumph OEM headlight ears, they cause the original Triumph headlight bowl to fowl on the clocks; so it's necessary to use the BAAK shallow headlight bowl, or an alternative of your choice.

We would recommend using a motorcycle jack to raise the front wheel off the ground, as when you remove the fork tube caps the springs will be compressed, causing the caps to shoot off, potentially damaging yourself or the bike, and leaking fork oil. 

Please note, leave a whole day to carry out this work. Do not rush or you will likely damage the motorcycle or worse. If you are not a competent mechanic, please ask a professional to carry out the work on your behalf. 

Tools:

• Allen key 4mm
• Allen key 8mm
• Socket 30mm
• Socket 38mm
• Socket extension & wrench
• Motorcycle jack
• Threadlock
• Rags / Padding / Protective wrap

1. Jack up the motorcycle using a suitable motorcycle jack and add thick padded protection to the gas tank and front mudguard.



2. To remove the existing headlight bowl, remove the two cross head screws located on the under side of the Triumph OEM headlight bowl and pull the headlight casing from the bowl. Disconnect the two plugs and store the headlight casing in a safe place. Remove the bolts, securing the bowl to the original headlight ears 

3. Carefully thread the existing Triumph OEM headlight bowl from the wiring loom that sits inside, this is a bit tricky but just take your time and thread individual cables through one at a time if necessary. Put the headlight bowl in a safe place, ideally wrapped to avoid it getting scratched.

4. Prior to removing the handlebar riser clamps, be sure to slacken off the handlebar riser bolts on the underside of the top triple clamp, as shown below. We used a 14mm long reach socket, extension bar and a ratchet.

*It's difficult to slacken these off once you remove the handlebars, as the risers spin on top of the triple clamp.

5. Remove handlebar riser clamps using a 6mm allen key and carefully rest the bars on top of the tank protector. Proceed to then remove the handlebar riser clamps. 

6. Remove the large chrome nut on top of the stem tube, we used a cloth to protect the nut and a large adjustable spanner. The favourable tool would be an 38mm socket if you have one. Go steady!

7. Once the stem nut is removed, we move on to the fork tube caps. Make sure the front wheel of the motorcycle is just off the ground at this point to relieve the compression in the fork tube springs - otherwise you may get a bit of a shock! Using a 30mm socket carefully remove the fork tube caps. Wipe the excess fork oil with a clean cloth and keep the caps in a clean dry place before re-fitment. 



9. Slacken off the top triple clamp fork tube clamps with a 6mm allen key.



10. Before removing the top triple clamp, make sure the front mudguard is protected. It's also a good idea to wrap the clocks in a protective cloth to ensure they are no scratched during this process.

Carefully thread the handlebar cables over the top of the clocks so the bars are now resting on the cloth covering the front mudguard and proceed to remove the top triple clamp bracket. You can't remove it fully as the ignition is still hard wired into the bracket. Wrap the bracket for extra scratch protection if required. 



11. Remove the original indicator stalk and headlight ears from the top of the fork tubes. Be sure to keep the headlight ears and rubber gaskets in a safe place, should you wish to re-fit these items at a later date. 



12. Proceed to fit the new British Customs Headlight ears or new headlight ears of your choice. Slide the new ears on to the fork tubes.



13. Once both sides are installed, go through steps 10-4 working backwards, so the triple clamp brackets are re-installed, fork tube clamps tightened, handle bar risers re-fitted and new BAAK shallow headlight bowl is installed. It takes a while to thread the wiring loom through the hole in the rear of the headlight bowl, take your time and don't rush. All bolts should be threadlocked and torqued to the manufacturers recommendations.



14. We used Motogadget Mo-Blaze pin indicators for a super clean look. The indicator threads were actually used as a replacement for the bolts holding the BAAK shallow headlight bowl to the British Customs Headlight ears. Although you may wish to use bolts and run a different kind of indicator setup. (It did take some light modification to the headlight bowl to get these to fit).

15. To avoid chopping into the motorcycle wiring harness, we sourced the Triumph OEM corresponding female indicator plugs to wire in the new indicators.

Please note that if you are using the British Customs headlight ears then you will need an aftermarket indicator setup, as the British Customs headlight ears do not offer a way for the existing indicator stalks to bolt up. 



16. Once the indicators are re-wired, check to see that the corresponding Left and Right turn signals are correct and the indicators are the right way round. 

Offer up the BAAK shallow headlight bowl light unit and check for clearance. Being that the new unit is shallower, there is less room for wiring, but after a few attempts and re-arranging the wiring in the headlight bowl it should be ok. Connect the new light unit (two plugs) and slide it into the headlight bowl. Secure the headlight bowl with the two cross head screws that come with the unit. 

17. The last step is to align the headlight ears on the fork tubes, by checking that there is enough clearance for the headlight bowl under the clocks. Secure the headlight ears using the allen key supplied in the kit.



Once you are happy with the installation, go over all of the connections and double check that everything is torqued as per the manufacturers recommendations and that bolts are threadlocked to prevent them from vibrating loose. Double check the headlight is secure, adjusted correctly for MOT purposes and that the indicators are working correctly. 

PLEASE NOTE: The information in this article is to be used as a guide only. If you are not a trained mechanic, please instruct a professional to carry out the work on your behalf. 

Ride Safe!