SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> Headlight Swap Options ???
/cgi-bin/YaBB.pl?num=1443653336

Message started by DesertRat on 09/30/15 at 15:48:56

Title: Headlight Swap Options ???
Post by DesertRat on 09/30/15 at 15:48:56

Do we have any options when it comes to larger headlight?

Any other Suzuki models with a larger headlight fit our bikes stock mount without heavy fabrication?

Title: Re: Headlight Swap Options ???
Post by Kris01 on 09/30/15 at 16:02:08

A Marauder headlight supposedly fits. There are threads about it here.

Title: Re: Headlight Swap Options ???
Post by verslagen1 on 09/30/15 at 17:07:34

Intruder and marauder have similar headlights.
Some have metal buckets and are larger.
Some have the same mounting holes.
Look at the pictures and make a guess
Modding one that's a little off is easier than making new

Title: Re: Headlight Swap Options ???
Post by Kris01 on 09/30/15 at 18:20:14

If you find one that is larger and is a direct fit with little to no mods needed, detail the installation here...PLEASE!

Title: Re: Headlight Swap Options ???
Post by DesertRat on 09/30/15 at 20:42:11

found the post discussion on the marauder headlight swap. no consensus reached in 4 pages of posts. i did run across the same issues trying to find the 800 headlight, but quite a few 1400 lights on ebay. but they look to be the same size as our stock light or were busted up. I want a 7" bucket and lens. guess it's time to hit the salvage yards.

Title: Re: Headlight Swap Options ???
Post by verslagen1 on 09/30/15 at 20:50:10

for the money they want, I'd buy a new 7" side mount light and the mounts.

Title: Re: Headlight Swap Options ???
Post by Paladin. on 09/30/15 at 20:51:22

My way: http://www.andruschak.net/savageriders.com/paladin/images/headlight2.jpg
Four pieces of aluminum angle, 8 small nuts/bolts on the sides, two bolts down to the triple tree, one bolt up for a standard Harley mount.
Got mine on eBay for $10 plus $10 shipping. Guy said it was for a hot rod, just one, didn't know it was from a motorcycle.

Title: Re: Headlight Swap Options ???
Post by DesertRat on 09/30/15 at 21:19:26

I found one that looks like it "might" work. put in an offer, will see. if so, I'll post data and pics of the mod.

Title: Re: Headlight Swap Options ???
Post by Dave on 10/01/15 at 04:06:26

You have 2 choices for a headlight swap.

1) Buy one that is the center bottom mount like Harley, and make an adapter to work with the 2 bolt holes in the bottom fork yoke.

http://www.dimecitycycles.com/7-inch-complete-headlight-assembly-gloss-black.html

You can also go to eBay and find a lot of new or used bottom mount headlights that are very affordable. Lots of folks take stuff off and put it up for sale at a good price.

http://www.ebay.com/itm/95-HARLEY-DAVIDSON-DYNA-WIDE-GLIDE-FXDWG-OEM-FRONT-HEAD-LIGHT-HEADLIGHT-LAMP-/201395956622?hash=item2ee4226b8e&vxp=mtr

2) Buy the side mount headlight and work to add the brackets to the forks. We have 38mm fork tubes and pretty wide fork tube spacing, and this is somewhat of an odd size when you go to buy the brackets. You most likely will have to use some rubber inner tube or similar material to make shims to fit the more common 39mm fork tubes, and you will have to put a bit of a kink or use spacers in the brackets to allow the bracket to fit squarely against the mounting points on the bucket.

If I were doing a 7" headlight....I would get a bucket like this one.

http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-electronic-lighting-parts-satin-black-7-inch-british-headlight-bucket-66-65068.html

And I would put this headlight assembly in it. This is the absolute best "Old School" headlight you will ever find.

http://www.rallylights.com/hl79562-hella-7-round-h4-e-code-headlamp-each.html

The Cibie 7" headlight looks a bit cooler....the lens has is smoother and looks more like crystal.

http://www.danielsternlighting.com/products/products.html

You will need to find some kind of mount like this:

http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-chassis-lighting-parts-lightweight-black-headlight-brackets-66-35810.html

Title: Re: Headlight Swap Options ???
Post by justin_o_guy2 on 10/01/15 at 04:41:03

Paladin had one that looked stolen from a narrow gauge steam locomotive. It was cool. Ask him what it came from.

Title: Re: Headlight Swap Options ???
Post by JutMan on 10/01/15 at 04:56:52

This is an interesting options with those side mounts.

http://www.dimecitycycles.com/7-1-2-inch-satin-black-modern-british-style-headlight-assembly.html

Title: Re: Headlight Swap Options ???
Post by Ultimafuego on 10/01/15 at 08:07:39

You have the right idea there Dave, I did that to mine, except for mine is an old 5.25 headlight. It was quick to get it on the road and I will be upgrading soon. But I did use the same headlight brackets you referred too.

http://i1377.photobucket.com/albums/ah63/ultimatrifire/S40/IMAG0341_zpsjvoba8py.jpg

Title: Re: Headlight Swap Options ???
Post by WD on 10/01/15 at 08:33:07

Vulcan 800 and 1500 are metal 7 inch bottom mount, and the mounts are really close to what our small plastic junk bucket uses.

VS800/1400 is the same part number as stock Savage/S40.

The locomotive headlight is a 10 inch, and the gentleman that owned it (not Paladin) is deceased.

I run a high set 7 inch metal side mount. British replica with a traditional looking lens and H4 bulb. Mount it high, and you have more room to dial in where the beam hits in front of you. Side mounts allow you to perfectly dial where the beam hits in the lane or shoulder. If you buy a side mount, go ahead and get the Emgo mounts and bucket, just paint them and replace the hardware with stainless before installing. You can buy Triumph replica turn signals that mount through the headlight "ears" and delete the factory plastic junk from your forks at the same time.

Best parts swap ever on either of my Savages is the combination of full rear fender and high mounted headlight. They make the factory installed 1920s Scott (long out of production English bike) knock off fuel tank look good.

Tracker or touring handlebar will complete the look and dramatically improve the bike's ergonomics.

http://i1277.photobucket.com/albums/y490/mphsgal/Jeffs%20pix/Sam/Sam4_zpsfb9945f0.jpg

http://i1277.photobucket.com/albums/y490/mphsgal/Jeffs%20pix/Sam/f4e723a2-3498-4570-a862-3e02bd606def_zps2sliglbz.jpg

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/01/15 at 18:21:44

well, the guy accepted my offer, $30 with FREE shipping.
It's from a 97 Suzuki Intruder VS1400

Now I read WD post that it is the same size as our stock light.

So I'm wondering what model the guy in the blog post pulled his headlight from?

I need exact year and models of 7" buckets that fit our bikes without heavy mods.

Dave has some great ideas. I thought our fork tubes were 39mm?? I did find, on ebay, some nice cast aluminum universal mounts that come with rubber inserts to fit other sizes that are made to mount that 7" CB style bucket headlight.

Title: Re: Headlight Swap Options ???
Post by verslagen1 on 10/01/15 at 18:35:42

Our forks are 38

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/01/15 at 18:51:25

Just put a mic on them 38mm. Where I got 39mm from is lost on me, way too much reading on this forum possibly mixing up stuff

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/02/15 at 12:02:18

OKAY folks, here's data from ebay seller:

1987-1994 KAWASAKI VULCAN 1500 HEADLIGHT is:

5-3/4"

Title: Re: Headlight Swap Options ???
Post by Siper2 on 10/02/15 at 12:25:18

I'm brand new here, but Delkevic makes a nice side-mount 7" light. I just picked one up for my Yamaha conversion. Check eBay for "Delkevic motorcycle headlight," they're usually about $70.

Very well-received by the folks on XJRider.com.

Apologies if it's been suggested already!

=S2=

Title: Re: Headlight Swap Options ???
Post by WD on 10/02/15 at 15:56:16

745543554244625144300 wrote:

OKAY folks, here's data from ebay seller:

1987-1994 KAWASAKI VULCAN 1500 HEADLIGHT is:

5-3/4"

That would be the VN1500A, the worst big v twin they made. When I reference the series think , Classic or Drifter 1500s. The 1500A is only good as a wheel and spacer donor to run a 21 on a Classic, Drifter or Nomad. Or as Cobra brand full rear fender donor for the 800A.

Even real (pre 1965) HD Big Twins and the side valve 45 used high mount headlights until the Hydraglide fork came out in 1949. Real versions with springer forks kept the high mount headlight. Even the Evo and Twinkie springer fork models had a high mount headlight.

Get a side mount. Function first, Savage electrical system is weak and the large bucket/reflector makes huge positive difference.

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/02/15 at 19:36:15

WD, i got the info directly from the seller of the Kawasaki headlight, they own a salvage yard and list on ebay.

another seller came back with 1997 Suzuki Intruder 1400 VS1400 Headlight is 7", I ordered it and will report the swap

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/05/15 at 17:23:20

Bad News -

1997 Suzuki Intruder 1400 VS1400 Headlight is 5-1/2" headlight, same as ours. Seller was mistaken.

Sent it back. Still looking for a 7" bolt on swap.

Title: Re: Headlight Swap Options ???
Post by Kris01 on 10/05/15 at 20:01:10

Apparently 5-1/2" is a pretty common size. :(

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/06/15 at 05:37:33

I may check the salvage yards this weekend, time permitting.

Title: Re: Headlight Swap Options ???
Post by WD on 10/06/15 at 10:32:34

VN800B or Drifter. VN1500 Classic Drifter Nomad. Bottom mount 7" headlights, some are metal some are plastic, year dependent. The V2k (VN2000, which is really 2.3l and some change) has a couple light options depending on which model you find.

Bigger Star cruisers have 7" headlights.

Some Honda cruisers had a 7" light.

Grab some old style fenders while you are there. A narrowed large displacement Virago front fender looks killer on hot rodded Savages.

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/06/15 at 12:07:10

WD,

Im hoping you're measuring the headlight and not the bucket. That is what the seller did, the bucket was close to 7" dia., but the headlight is the smaller 5-1/2".

Title: Re: Headlight Swap Options ???
Post by Kris01 on 10/06/15 at 19:40:59

Maybe you're not aware of WD's expert knowledge of 2 wheels in general. I'm sure he's correct! ;) ;D

Title: Re: Headlight Swap Options ???
Post by norm92de on 10/07/15 at 12:18:11

Triumph has a pretty nice chrome headlight. It would need "ears" to attach it to an S40. The Thruxton mounts are made for 41mm tubes so would need to be modified in some way, The Triumph mounting bolts etc. are s.s. and do look nice.
Probably Triumph prices will be high?

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/07/15 at 14:45:08

Norm92de,
the ear mount headlight will be my next choice if I cannot locate a direct OEM swap from a different model Suzuki.

Kris,
WD reminds me of some of my professors, or a physics lecture, he might as well be speaking LATIN, he's got a ton more knowledge than I. Just a simple farm boy and I have a hard time following him with all the models and specs and such.

Title: Re: Headlight Swap Options ???
Post by Kris01 on 10/07/15 at 17:42:46

Haha, you're not alone!

Title: Re: Headlight Swap Options ???
Post by Albert Verdugo on 10/07/15 at 23:05:56

And what about a headlight switch?

Does anyone had made a switch to turn on and off the headlight (after turning the key CCW)?

:-?

Title: Re: Headlight Swap Options ???
Post by Dave on 10/08/15 at 03:18:47

1A38312C383A590 wrote:

And what about a headlight switch?

Does anyone had made a switch to turn on and off the headlight (after turning the key CCW)?

:-?

What would be the purpose in turning the headlight ON when the bike is turned OFF? You can accomplish almost the same thing by turning the ignition switch to ON....then turning the STOP switch on the right handlebar to kill the ignition circuit.

Adding a switch to turn the headlight off when the bike is running is easy - the switch could be added to the ground wire from the headlight....that way it would be able to turn off both the low/high beams with a single switch.

In another thread....we are discussing the fact that the charging system in our bike is always charging at full capacity, and the regulator/rectifier has to bleed off any power that is not being used by the bike. Therefore the charging system is designed to use up most of the available power, with just a bit extra for battery charging. When the battery is charged any excess power is burned off by the regulator as heat.

If you turn your headlight off while riding you are not saving any electrical power - you are just diverting it to the regulator to be burned off as heat.....we don't know how much extra power the regulator can burn off and not overheat.

If you goal is to get some electrical power for running heated gear when it is cold, I don't think anybody believes it is a good idea to ride with the headlight turned off - you need to be as visible as possible and folks thees days expect to see a headlight/running light on any vehicle that is in motion. The 2004 and later bikes are wired so the headlight turns off when the starter switch is engaged so the full battery power can be diverted to the starter and ignition system.

Title: Re: Headlight Swap Options ???
Post by Steve H on 10/08/15 at 03:59:21

In many states, it is illegal to ride with the lights off.

Title: Re: Headlight Swap Options ???
Post by WD on 10/08/15 at 07:17:40

5B6279632021100 wrote:

Maybe you're not aware of WD's expert knowledge of 2 wheels in general. I'm sure he's correct! ;) ;D

I'm not an expert by any stretch. Have spent 39 years spinning wrenches in rod, kustom, boat and motorcycle work bays, since I was age 4. Have owned in excess of 100 street motorcycles, have either restored or customized each one.

That said, I still can't fix 2 strokes. I throw them away and buy a replacement whatever got damaged. I don't work on damaged OHV, let alone OHC cylinder heads. I neither understand or work on fuel injection. Computer controlled vehicles get scrapped, not repaired, unless the engine can accept a carburetor and points distributor.

Trust me, I'm a dinosaur. The 700r4 in my K1500 lost 3rd and 4th, it is now a farm only truck. My sat for the last 21 years 1949 Dodge, and sat for the last 4 years 1969 Dodge trucks are going back in service to replace the 1992 Silverado. They make sense, it does not.

FYI, headlights are always measured off the lens size, never the bucket size. ;)

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/08/15 at 13:46:50

see WD, there you go again speaking LATIN. I was lost until you said:

Quote:

FYI, headlights are always measured off the lens size, never the bucket size.

that I understood :D

Title: Re: Headlight Swap Options ???
Post by Albert Verdugo on 10/08/15 at 21:31:26

6A515C4B5A564D4B5058554A390 wrote:

[quote author=1A38312C383A590 link=1443653336/15#29 date=1444284356]And what about a headlight switch?

Does anyone had made a switch to turn on and off the headlight (after turning the key CCW)?

:-?

Title: Re: Headlight Swap Options ???
Post by copterdoc on 10/10/15 at 12:36:46

704F4E775B543A0 wrote:

This is an interesting options with those side mounts.

http://www.dimecitycycles.com/7-1-2-inch-satin-black-modern-british-style-headlight-assembly.html

I have the 7 1/2 inch headlight that Jutman pointed out on the first page of this thread from Dime city. Very happy with it. I have the small bulb set up as a daytime running light and installed a simple waterproof toggle switch from autozone for the main light.

Title: Re: Headlight Swap Options ???
Post by copterdoc on 10/10/15 at 12:37:38

Pic

Title: Re: Headlight Swap Options ???
Post by copterdoc on 10/10/15 at 12:38:25

pic

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/10/15 at 17:06:15

7A76696D7C6B7D767A190 wrote:

pic

nice setup copterdoc. Do you have a pic straight-on, level with headlight ?

Title: Re: Headlight Swap Options ???
Post by copterdoc on 10/11/15 at 06:02:17

Here ya go.

Title: Re: Headlight Swap Options ???
Post by copterdoc on 10/11/15 at 06:02:59

Another

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/11/15 at 07:41:31

yeah, that's it.

These headlights "FIT" the look of our bikes better than stock.

Title: Re: Headlight Swap Options ???
Post by RB on 10/11/15 at 09:45:54

Greetings
My solution is shown in the attached pic.
The headlight and brackets from DCC and the turn signals are from a local supplier KAPSCO moto. The headlight is bright and has lots of room inside to hide wiring. It was plug an play on my bike.
Good luck with it!!

Title: Re: Headlight Swap Options ???
Post by Kris01 on 10/11/15 at 09:58:48

What size and model # headlight? Are the brackets heavy duty enough? Any vibration from the brackets?

I'm looking to swap mine to a 7" but I can't find a decent looking chrome light that I like. I'm glad you mentioned the room inside. I was a little leery of buying aftermarket because I didn't know how much space was inside.

As long as the headlight uses an H4 bulb, I won't have to do any changes to the headlight plug, right?

Title: Re: Headlight Swap Options ???
Post by RB on 10/11/15 at 13:45:34

No changes required for the wiring harness (for my install H4) and the DCC parts I used are;
1. 66-3590 7" Gloss Black Modern British Style Headlight Assembly
2. 66-35850 Chrome Headlight Mounting Brackets

This stuff is more than heavy duty enough. (No Vibration)
I drilled the brackets to accept some turn signal mounts and I think the whole package works great and looks good.

Title: Re: Headlight Swap Options ???
Post by Kris01 on 10/11/15 at 19:13:38

Thanks. I might go that route. I've just about given up on finding a stock 7" headlight housing. Supposedly the Marauder had them but so far everyone is finding 5-3/4" housings.

Title: Re: Headlight Swap Options ???
Post by DesertRat on 10/11/15 at 19:36:34

Kris, Im still on the hunt my friend ...

Title: Re: Headlight Swap Options ???
Post by verslagen1 on 10/11/15 at 19:51:11

A while ago, I found a vegas headlight on fleabay.
2x H8/H11 bulbs
ended up making a T shaped adapter to mount it.
I usually like a flyshield but this headlight is big enough to hide behind.
http://suzukisavage.com/yabb2.2/Attachments/beast5-28-15.jpg

Title: Re: Headlight Swap Options ???
Post by DesertRat on 03/26/16 at 16:14:59

UPDATE - Mystery Solved

Just in case anyone searches this, the direct headlight swap can be found here in the Tech Section

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1458860497

Title: Re: Headlight Swap Options ???
Post by justin_o_guy2 on 03/26/16 at 19:27:34

Paladin had a headlight, looked like it came off a steam locomotive.