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10th November 2010
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Biker
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Join Date: Nov 2010
Location: Oceanside CA
Posts: 8 Sportster/Buell Model: XLH Sportster/Buell Year: 1965 Other Motorcycle Model: CB400F, H1, 1990 GSXR
Reputation: 10
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Need Help - mounting a headlight inside a nacelle of a 65 XLH
Does anyone know how the headlight is installed inside the nacelle of a 1965 XLH? I recently picked up a 65 XLH and want to restore it to its original condition. It presently has the standard sportster headlight but I have all of the original chrome nacelle sheetmetal parts. Please help
Thanks,
Neil
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10th November 2010
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Rider Of The Iron Steed
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Join Date: Dec 2003
Location: London, ON Canada
Posts: 23,699 Sportster/Buell Model: XLH Sportster/Buell Year: 1978
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Sorry, cannot help with this one. Someone will be along with some ideas. Welcome! to the IronHead forum.
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10th November 2010
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XL FORUM TEAM MEMBER
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Join Date: Jun 2009
Location: Sunshine Coast
Posts: 1,610 Sportster/Buell Model: XLB, XLCH, Sporton Sportster/Buell Year: 1962 Sportster/Buell Model #2: XLCH Sportster/Buell Year #2: 1966 Other Motorcycle Model: XLCH (Another one) Other Motorcycle Year: 1966
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The headlights for the XLH and XLCH are different. The XLH HL mounts at the bottom and requires a mount that bolts to the bottom of the triple tree.
Best bet here is to check the parts manual. It will show you the required parts.
If you don't already have one the XLH headlights are rare and pricey (from my point of view - not pricy if your used to buying new Ducati or even Suzuki for that matter).
Cyclewarehouse online have 2 NOS ones at the moment - 399 and 499 bucks from memory. If I was restoring I'd grab one of them now.
Speedo mount is another hard to get part. I paid $100 for a NOS one a while back.
__________________
"I know only too well the evil that I propose. But my inclinations get the better of me."
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10th November 2010
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Biker
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Join Date: Nov 2010
Location: Oceanside CA
Posts: 8 Sportster/Buell Model: XLH Sportster/Buell Year: 1965 Other Motorcycle Model: CB400F, H1, 1990 GSXR
Reputation: 10
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Does the XLH and XLCH use the same headlight housing but different mount or is the XLH a completely different housing?
Where can I find a parts manual? I've searched all over the internet and bought a service manual but cannot find an illustration to show me how its mounted.
I have the stock spedo and speedo mount and originally thought the light housing mounted to the mount.
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10th November 2010
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Biker
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Join Date: Nov 2010
Location: Oceanside CA
Posts: 8 Sportster/Buell Model: XLH Sportster/Buell Year: 1965 Other Motorcycle Model: CB400F, H1, 1990 GSXR
Reputation: 10
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Do you have the link to the xlh headlights on cyclewarehouse? I cant seem to find them.
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10th November 2010
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Senior Master Custom Bike Builder
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Join Date: May 2007
Location: Puget Sound--Washington State
Posts: 3,832 Sportster/Buell Model: Sportster XLH Sportster/Buell Year: 1961 Sportster/Buell Model #2: Sportster XL Sportster/Buell Year #2: 1957 Other Motorcycle Model: XLH 62, 65, 68, FLH 1970
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Yeah, cycle Warehouseonline has a NOS -65 headlight for $399. I am very careful and usually respectful of vendors, but without going on a diatribe, this guy is not to be trusted. It's a rare headlight, though, and with ebay's new policies, you do have some protection. Believe it or not, they often go for more than that--I've seen used ones go for five, but that was before the meltdown. Still, for a complete unit--door, bucket, and bulb and plug, that's not an unreasonable price.
The -65 headlight housing and door is identical to the -59 headlight. The only difference is the 12 volt bulb, so any of them will be correct for you bike.
Here's the link:
http://cgi.ebay.com/ebaymotors/NOS-G...item19bff2898b
You also need a different mounting bracket and some hardware. The bracket you need bolts (with special bolts, of course) to the to two threaded bosses on the lower triple tree. The Nacelle simply goes over the entire works, mounting to the top and bottom triple tree.
Be sure your top triple tree has the threaded steel inserts. NOS parts used to have the correct steel inserts, but I don't know if they still do.
I'm doing a 65XLH restoration as well, and after several major hangups should have it completed by spring. I'm by no means an expert, but I think I have pretty good knowledge on this particular model. If there's anything you need or need to know, give me a holler.
__________________
If I could only live at the pitch that is near madness
When everything is as it was in my childhood
Violent, vivid, and of infinite possiblilty:
That the sun and moon broke over my head.--Richard Eberhart
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10th November 2010
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Senior Master Custom Bike Builder
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Join Date: May 2007
Location: Puget Sound--Washington State
Posts: 3,832 Sportster/Buell Model: Sportster XLH Sportster/Buell Year: 1961 Sportster/Buell Model #2: Sportster XL Sportster/Buell Year #2: 1957 Other Motorcycle Model: XLH 62, 65, 68, FLH 1970
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PS The best source of correct hardware (by far) is Old Dude. If you don't know about him, I'll post the link
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10th November 2010
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Senior Master Custom Bike Builder
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Join Date: May 2007
Location: Puget Sound--Washington State
Posts: 3,832 Sportster/Buell Model: Sportster XLH Sportster/Buell Year: 1961 Sportster/Buell Model #2: Sportster XL Sportster/Buell Year #2: 1957 Other Motorcycle Model: XLH 62, 65, 68, FLH 1970
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Pictures please.
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10th November 2010
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Biker
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Join Date: Nov 2010
Location: Oceanside CA
Posts: 8 Sportster/Buell Model: XLH Sportster/Buell Year: 1965 Other Motorcycle Model: CB400F, H1, 1990 GSXR
Reputation: 10
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Wow I didn't realize lights went for that much. Are there any aftermarket headlight assembly that might work as a replacement? Do you know where I can get a bracket or do you have a picture of the headlight assembly/ bracket without the nacelle. I have access to a machine shop so I may be able to machine a bracket. I'll try to post a picture of my bike so far. It was in storage for 20 years and has a 75 front end but it came with a tub full of original parts. I did get it running last week so mechanically it works good. Thanks for the help so far this is a great site.
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10th November 2010
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Senior Master Custom Bike Builder
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Join Date: May 2007
Location: Puget Sound--Washington State
Posts: 3,832 Sportster/Buell Model: Sportster XLH Sportster/Buell Year: 1961 Sportster/Buell Model #2: Sportster XL Sportster/Buell Year #2: 1957 Other Motorcycle Model: XLH 62, 65, 68, FLH 1970
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I can post pictures of anything you need. The parts catalogs are obtainable and for restoration purposes probably more useful even than the manuals. I actually have the quite rare -65 parts catalog which is the best option for our bikes.
You can probably find a light that will work at a car swapmeet. I have one that's pretty close, in fact it has the same door, that I found, but it's pretty rough.
I will be starting a new thread on my 65 assembly soon. It should help.
By the way, welcome to the site.
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