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7” headlight, headlight, headlight bucket, headlight conversion

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  #1  
Old 4 Weeks Ago
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Maxeffort Maxeffort is offline
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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.




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Last edited by Maxeffort; 4 Weeks Ago at 16:35..
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Nice job !!!
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Nicely done and documented, thank you, have a similar conversion planned for my 2006 "R".
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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.
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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...
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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"
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Looks great!. Reminds me of the old '78 Yamaha 650, I put 77k on way back when. A real "Retro" look.
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