The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Electrical > Sportster Motorcycle Lighting
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Active Threads
0 XLCH Crazy voltage spike
Last Post: Seeny
Posted On: 19 Minutes Ago
Replies: 23
Views: 1,334
0 Hello from Az
Last Post: shanneba
Posted On: 31 Minutes Ago
Replies: 8
Views: 66
0 foo foo foo foo
Last Post: the yukon sizzler
Posted On: 40 Minutes Ago
Replies: 0
Views: 12
0 Another ultima iggy query.
Last Post: the yukon sizzler
Posted On: 52 Minutes Ago
Replies: 25
Views: 1,005
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Stairman
Posted On: 1 Hour Ago
Replies: 45,212
Views: 7,131,751
0 Hot Rods, Rat Rods, and Customs.
Last Post: Stairman
Posted On: 1 Hour Ago
Replies: 3,728
Views: 456,490
0 Hottie of the day, no nudity.
Last Post: Stairman
Posted On: 1 Hour Ago
Replies: 14,424
Views: 1,343,041
0 Iree's late night cafe
Last Post: rubine
Posted On: 1 Hour Ago
Replies: 1,317
Views: 166,195
0 Wiring Diagram in autocad
Last Post: Folkie
Posted On: 1 Hour Ago
Replies: 85
Views: 45,026
0 Wet Sump Ifo, fix and tools
Last Post: ccmman
Posted On: 2 Hours Ago
Replies: 45
Views: 3,251
0 Carburetor opinions
Last Post: Ferrous Head
Posted On: 3 Hours Ago
Replies: 17
Views: 322
0 Transformer XR1200
Last Post: Bryan1976
Posted On: 6 Hours Ago
Replies: 99
Views: 8,124
0 Transmission Issue or clutch?
Last Post: Iron Mike
Posted On: 7 Hours Ago
Replies: 20
Views: 872
0 rotating engine by hand
Last Post: Hippysmack
Posted On: 7 Hours Ago
Replies: 3
Views: 58
0 Clean my Clock
Last Post: Hippysmack
Posted On: 7 Hours Ago
Replies: 2
Views: 126
0 1960 XLCH in the UK
Last Post: sportsterpaul
Posted On: 8 Hours Ago
Replies: 149
Views: 14,016
0 MAP Request-TC88A
Last Post: 1Scooter
Posted On: 8 Hours Ago
Replies: 5
Views: 75
0 IH sidecar road racer
Last Post: sportsterpaul
Posted On: 8 Hours Ago
Replies: 1
Views: 99
0 Keep & Kill
Last Post: Yakcm2
Posted On: 8 Hours Ago
Replies: 13,940
Views: 781,729
0 Rico Lutsey aka Rico 05R
Last Post: sportsterdoc
Posted On: 10 Hours Ago
Replies: 22
Views: 580
0 Change jets without removing carb?
Last Post: sportsterdoc
Posted On: 10 Hours Ago
Replies: 22
Views: 3,811
0 Hot Chicks on Hot Bikes
Last Post: trainman
Posted On: 10 Hours Ago
Replies: 10,314
Views: 1,785,947
0 Hello from the Northeast US.
Last Post: 84cj
Posted On: 10 Hours Ago
Replies: 20
Views: 229
0 This week on Craig's list
Last Post: A Seabee
Posted On: 10 Hours Ago
Replies: 4,368
Views: 522,699
0 Lets See your bike on a scenic overlook
Last Post: Lone Rider
Posted On: 11 Hours Ago
Replies: 137
Views: 25,359
0 Next Project - 1275cc Engine Build - Which Year & Why...?
Last Post: rocketmangb
Posted On: 12 Hours Ago
Replies: 12
Views: 509
0 crank case breather
Last Post: Hippysmack
Posted On: 12 Hours Ago
Replies: 20
Views: 577
0 SERIOUS 1275 engine issues!! PLEASE HELP!!
Last Post: Boil1337
Posted On: 13 Hours Ago
Replies: 54
Views: 6,910
0 Food porn
Last Post: sportsterpaul
Posted On: 13 Hours Ago
Replies: 1,622
Views: 275,922
0 My new LED headlight
Last Post: Stairman
Posted On: 13 Hours Ago
Replies: 6
Views: 166
More...
Members Birthdays
irvingjr (71), 909XR (62), Ghost_FL (60), mark R (59), TWISTED (46), spade (44), Drivethis29 (39), dodgetrucken (34)
Tags
7” headlight, headlight, headlight bucket, headlight conversion

Sponsored Links
Reply
 
Share Thread Tools Display Modes
  #1  
Old 4 Weeks Ago
Maxeffort's Avatar
Maxeffort Maxeffort is offline
Momentary Specialist
 
Join Date: Aug 2016
Posts: 461
Sportster/Buell Model: XL1200
Sportster/Buell Year: 1996
Other Motorcycle Model: ST1100
Other Motorcycle Year: 1999
Reputation: 664736
Maxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond repute
Default 7” Headlight conversion on solid mount

I just completed the 7” headlight conversion on a 1996, 1200.

I used the Bikemaster 7” headlight, part number 152455.
It’s a modern British style as used on newer Bonneville’s.

It looks to be a high quality headlight assembly. Made in Taiwan, with a nice fit and finish. It has a nice big wiring entrance and includes a rubber grommet. It also has three tabs inside for securing wires.

The screw seen in the bezel is an adjuster.






I mounted it with chrome plated Aluminum clamps. These were a bargain. Nice chrome finish and seem to be quality die-cast chinesium. The fit on 39 MM fork tubes with the supplied spacers was a little loose. Two layers of electrical tape, securing the halves together gave a good fit.
You do have to slide the forks down to install them. I just jacked the bike up, removed the brake caliper, loosened the triple tree pinch bolts and slid them down. (I didn’t remove the fender or wheel)




There is a bunch of wiring inside the bucket. I removed the connectors from the male 12 pin Deutsch connectors only, making a little chart of wire locations for each. I left the female 12 pin connnectors on the wires. I clipped the light plug off. Then was able to remove all the wiring and old light bucket.

There was just enough room to push the female 12pin Deutsch connectors through the new buckets wiring hole. You have to slide the grommet over the wiring first, put the connectors in, then re-install the grommet.

I butt spliced the new headlight plug in. I would have liked to put new Deutsch pins on, but didn’t have any in stock.

The tach and speedo were remounted to the top triple tree where the old Eyebrow mounted. This hides most of the wiring. The speedo bracket holes have to be elongated a bit. Rubber faucet washers were used to provide some isolation. It’s secured with stainless bolts on top of 3/8’s spacers.

The headlight bucket is just a little wide for the forks and brackets. I had to make two thin nylon spacers so there wasn’t a small angled gap at the light mounting points. I used nylon washer bushings from the hardware store and just sanded them to fit. If steel mounting brackets were used, the could be bent a bit, but not the aluminum.

The other option for a side mount would be the Lucas style 7” as the mounting points are indented. I like the big British headlight though and it has the most room for wiring.

It’s mounted with Stainless washers and stainless metric socket head screws.







With the headlight assembly, mounting clamps and hardware, I’ve spent approximately $100. On the conversion.



I think it looks good and it does throw a lot of light. I wanted to stay with the traditional headlight lens, not a daymaker.




__________________
Sleepy Labeef rides again!

Last edited by Maxeffort; 4 Weeks Ago at 16:35..
Reply With Quote
  #2  
Old 4 Weeks Ago
old dog old dog is offline
Biker
 
Join Date: Nov 2017
Location: Scarborough,N.Yorks
Posts: 88
Sportster/Buell Model: Nightster
Sportster/Buell Year: 2011
Reputation: 10
old dog is an unknown quantity at this point
Default

Nice job !!!
Reply With Quote
  #3  
Old 4 Weeks Ago
sportsterpaul's Avatar
sportsterpaul sportsterpaul is offline
XL FORUM TEAM MEMBER
 
Join Date: Jan 2009
Location: In a swamp/Michigan
Posts: 13,807
Sportster/Buell Model: XL1460C
Sportster/Buell Year: 2000
Sportster/Buell Model #2: XL1200R
Sportster/Buell Year #2: 2006
Other Motorcycle Model: XL1200R
Other Motorcycle Year: 2004
Reputation: 10071290
sportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond repute
Default

Nicely done and documented, thank you, have a similar conversion planned for my 2006 "R".
__________________
I.B.A.#26543, Growing old-Mandatory/ Growing up-optional. Men do not quit playing because they get old, they get old because they stop playing!

The XL Forum Sportsterpedia:
http://sportsterpedia.com/doku.php/start
Reply With Quote
  #4  
Old 4 Weeks Ago
mikeLI_77's Avatar
mikeLI_77 mikeLI_77 is offline
XL FORUM LIFE MEMBER
 
Join Date: Nov 2004
Location: Long Island, NY
Posts: 4,803
Sportster/Buell Model: XL1250c
Sportster/Buell Year: 2002
Reputation: 1427232
mikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond reputemikeLI_77 has a reputation beyond repute
Default

Looks good. Smart idea going with the side mounted headlight on a solid mount. I had a 7" and used a knockoff fatboy headlight bucket off ebay that ended up breaking wear the bucket meets the mounting tabs and then I bought a genuine hd version which did the same so I went back to the stock size bucket.
__________________
2002 XL1200C (originally)



Hammer 1250 kit W/ 30° reverse dome pistons, billet 2.25" crush forward offset open air cleaner, billet intake manifold, Impact 560's, Sledge Hammer pushrods, Buell XB heads with crush level head porting, Mikuni HSR 45, 177.5 main, 25 slow, Clip 4th slot from top, Jim's powerglide II lifters,
Supertrapp supermeg exhaust 20 disks and open end cap, S&S roller rockers, Alto Carbonite clutch, Energy One 15% heavier spring, Daytona twin tech single fire ignition 1005s
Ricor intimnators, 13" Ricor IAS shocks, Brembo dual disk setup from 2012 street glide w/ matching brembo street glide master cylinder,
Koso T&T multi function speedo/tach

Dyno Sheet
96.21 HP/88.70 TQ


States I Have rode through
Reply With Quote
  #5  
Old 4 Weeks Ago
sml1226 sml1226 is offline
Chief Know It All
 
Join Date: Apr 2015
Posts: 404
Sportster/Buell Model: XL1200R
Sportster/Buell Year: 2004
sml1226 has disabled reputation
Default

I had identical brackets when I tried a 7", and the castings cracked at the bolts before they even attempted to tighten down on the fork tubes. Hope yours are better than the junk I had...
Reply With Quote
  #6  
Old 4 Weeks Ago
Maxeffort's Avatar
Maxeffort Maxeffort is offline
Momentary Specialist
 
Join Date: Aug 2016
Posts: 461
Sportster/Buell Model: XL1200
Sportster/Buell Year: 1996
Other Motorcycle Model: ST1100
Other Motorcycle Year: 1999
Reputation: 664736
Maxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond reputeMaxeffort has a reputation beyond repute
Default

Quote:
Originally Posted by sml1226 View Post
I had identical brackets when I tried a 7", and the castings cracked at the bolts before they even attempted to tighten down on the fork tubes. Hope yours are better than the junk I had...
These seem ok. They have some "spring" to them at the clamp. Time will tell... you never know with "Chinesium Alloy"
Reply With Quote
  #7  
Old 4 Weeks Ago
Toejam503's Avatar
Toejam503 Toejam503 is offline
Air-Cooled Forever
 
Join Date: May 2010
Location: Dakota Territory
Posts: 2,688
Sportster/Buell Model: XL 1200 C
Sportster/Buell Year: 2006
Sportster/Buell Model #2: (Prev.Own)XLH Milw.Spec.
Sportster/Buell Year #2: 1981
Reputation: 4922057
Toejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond reputeToejam503 has a reputation beyond repute
Default

Looks great!. Reminds me of the old '78 Yamaha 650, I put 77k on way back when. A real "Retro" look.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



Sponsored Links
All times are GMT +1. The time now is 11:59.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC