A Guide To Triumph Headlamp Shells

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A Row Of Headlamp Shells
Motorcycle Headlamp Shells
A Guide To Triumph Headlamp Shells 9
Dave Porter Portrait 2
A Guide To Triumph Headlamp Shells 10

By Dave Porter, Customer and Technical Support at The Bonneville Shop

Table of Contents for Triumph Headlamp Shells

The headlamp shell is one of the most prominently displayed parts on a vintage British motorcycle, as it sits proudly between the forks and in front of the handlebar. All too often, a project motorcycle is acquired with a dented, rusted, or incorrectly fitted headlamp shell. Instinctively, many restorers will go right to the parts catalog to get the correct part number for the replacement shell, but alas, there is often no part number to be found. There may be a part number for “Headlamp Complete”, but that includes the rim, glass reflector, bulb holders, bulbs and switches.

Suppliers and retailers don’t generally offer a complete headlamp assembly, so if you’re new to old British motorcycles, how do you know what to look for? I have compiled a simple guide that will be useful in identifying the correct headlamp shell for most of the more common Triumph, BSA, and Norton models from the 1960s and 1970s. There are some variances in specifications during production runs, which may be why Lucas part numbers were not quoted in the parts catalogs, so hopefully this guide will be helpful in finding the correct headlamp shell for your restoration project

Lucas SS 700 7”

By far the most common style used in the unit-construction era, there were variations in drillings for ammeters, warning lights, and wiring grommets, as well as the size of the bosses for the mounting bolts, but they all shared the same chrome plated finish and 553248 headlamp rim:

  • 54520774 (99-9968) 1960-1965 Triumph 500 and 650 non-nacelle models. Ammeter and grommet hole only. 5/16-26 CEI bolt holes.
  • 59579 (99-9971) 1966 early specification Triumph 500 and 650 models with 12 volt battery. Ammeter and grommet hole. 5/16-26 CEI bolt holes.
  • 59579S (99-9971A) 1966 late specification Triumph 500 and 650 models. Ammeter, (1) warning light, and grommet hole. 5/16-26 CEI bolt holes.
  • 59734S (99-9971B) 1967 Triumph 500 and 650 models. Ammeter, lighting switch, (2) warning lights, and grommet hole. 5/16-26 CEI bolt holes.
  • 54523508 (99-9969) 1968-1970 Triumph 500 and 650 models. 1969-1970 BSA 500 and 650 models. Ammeter, lighting switch, (2) warning lights, and grommet hole. 5/16-26 CEI bolt holes.
  • 54526651 (99-7039) 1973-1978 Triumph 750 models. Lighting switch, (3) warning lights, and (1) grommet hole. 7/16-20 mounting bosses, retained by turn signal stalks.
  • 60279 60263 54526651 (99-7039A)1971-1974 Triumph 500 models. 1972-1974 Norton Commando MK2 models. Lighting switch, (3) warning lights, and (1) grommet hole. 7/16-20 UNF mounting bosses, retained by turn signal stalks.
  • 5411506 (99-7098) 60867 (06-6142) 1979-1982 Triumph T140 models. 1975 Norton Commando MK3. No warning light or switch holes, (3) grommet holes. 7/16-20 UNF mounting bosses, retained by turn signal stalks.

Lucas MCH 69 7”

Introduced for the 1969 model year, BSA and Triumph specified the 7” flatback headlamp shell for the 750 triples through the 1972 model year. 1971 saw the introduction of the MCH69 headlamp shell for the BSA and Triumph 650 models. Both versions of the MCH69 flatback shell are chrome plated and were fitted with the 553248 headlamp rim:

  • 54524099 (99-1221) 1969-1970 BSA A75 and Triumph T150 models. No warning lights, large rubber boot for wiring ingress. 5/16-26 CEI bolt holes.
  • 60260S (99-1009) 1971-1972 BSA and Triumph 650 models. (3) warning lights, lighting switch hole, and large rubber boot for wiring ingress. 7/16-20 UNF mounting bosses, retained by turn signal stalks.
54524099 01 Triumph Bsa 1971 72 650 T120 Tr6 Flatback 7 Headlight Shell Rim 1
54524099 01 Triumph Bsa 1971 72 650 T120 Tr6 Flatback 7 Headlight Shell Rim 1
Genuine Lucas Flatback Headlight Shell With Holes
Genuine Lucas Flatback Headlight Shell With Holes
T Triumph Trident T Bsa Rocket Flat Back Chrome Headlight Shell Emgo Pn T
T Triumph Trident T Bsa Rocket Flat Back Chrome Headlight Shell Emgo Pn T

Lucas MCH 66 5-3/4”    

   Specified for some BSA single-cylinder models, Triumph T20 Cub, and Triumph T100C and TR6C models, these were supplied by Lucas in black enamel or chrome plated shells. Both types use the 534343 chrome rim:

  • 54524000 58395 59665 (99-9974) Black enamel finished shell was specified for 1967-1970 BSA B44VS models and others, some with lighting switches, (1) warning light, and single grommet hole. Earlier versions had 5/16-26 CEI bolt holes, while the later shells had 5/16-24 UNF bolt holes.
  • 54524599 58395C (99-9973) Chrome plated shell, as specified for Triumph T100C and TR6C models from 1966-1970. Some versions were supplied originally with holes for lighting switches and warning lights. Reproduction MCH 66 shells are generally supplied undrilled to suit different models and model years, and with 5/16-24 UNF bolt holes. 1971-1972 MCH 66 shells had 7/16-20 UNF mounting bosses, and were retained by turn signal stalks.    
Gen Lucas Inch Headlight Black
https://www.thebonnevilleshop.com/product/genuine-lucas-triumph-bsa-5-3-4-headlight-shell-with-chrome-rim-pn-58395/GEN LUCAS INCH HEADLIGHT BLACK
C Gen Lucas Inch Headlight Chrome
C Gen Lucas Inch Headlight Chrome

   While this guide is not all-encompassing, it is intended to cover most of the common headlamp shells originally specified for 1960s and 1970s-era Triumph models. Most reproduction headlamp shells available from Lucas now are fitted with 5/16-24 UNF mounting bosses, aside from the 1971-onward shells, which are mounted using the turn signal stalks or bolts with 7/16-20 UNF threads.

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