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General Category >> Rubber Side Down! >> Replacement headlamp for '09 S40?
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Message started by wiscoz88 on 07/19/16 at 07:29:54

Title: Replacement headlamp for '09 S40?
Post by wiscoz88 on 07/19/16 at 07:29:54

I have a headlamp that is cracked on both sides of the mount, so I need to replace the entire unit. Shockingly the internet has failed me…the only guides I’ve been able to find just talk about replacing the bulb, and the only Suzuki replacements I’ve found don’t match the type of lamp/mount on my bike (‘09 S40). Not sure how easy it would be to convert to an aftermarket headlamp.

Anybody have a suggestion? I can post a picture of the mount tonight if needed.

Title: Re: Replacement headlamp for '09 S40?
Post by verslagen1 on 07/19/16 at 08:04:24

All you need to replace is the shell and I believe the S50 has the identical part.

But also if you're looking for a metal part...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1458860497

Title: Re: Replacement headlamp for '09 S40?
Post by striknein on 07/19/16 at 15:24:23

I have a stock headlight off an '07 for sale. It'll bolt right up.

You could also scour eBay for a 7" headlight off a Marauder; it took a couple months but I managed to score one for not a lot of money.

Mounting an aftermarket part is gonna be a crapshoot. It wouldn't be too much work to fab up a mount if you have the tools and the wherewithal though.

Are you also asking for specific instructions for removing the old headlight?

Title: Re: Replacement headlamp for '09 S40?
Post by batman on 07/19/16 at 16:10:41

Wiscoz, epoxy is your friend,you can put some in the cracks and then fill the entire area above the two mounting bolts to make it rigid,lighty sand the shell and paint . even if you don't like the look it will last to you find one better,keep it on a shelf for a backup.

Title: Re: Replacement headlamp for '09 S40?
Post by badwolf on 07/20/16 at 05:54:32

I used a aftermarket steel bucket with a bottom "post" mount when I went to the LED bulb. Used a piece of 3/8" aluminum about 3'' square, 2 holes in the back to match the stock bolts, and one in the front for the ''post''. That gives you a lot of flexibility.