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VZ800 7" Easy Daymaker LED insert (Read 126 times)
ruckus430
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VZ800 7" Easy Daymaker LED insert
01/02/18 at 00:46:43
 
2002 Suzuki Savage, suzuki VZ800 headlamp,and a 7" daymaker led copycat
This mod is simple its been established that the vz800 headlamp is a perfect swap and with minor cutting of the old headlamp you can fit a 7" daymaker type led insert that is plug and play with the savage 3 prong harness.

This is the VZ800 headlamp I will use this diagram to discribe the mods
Housing https://www.partzilla.com/catalog/suzuki/motorcycle/2000/marauder-vz800/headl...  
headlamp https://www.partzilla.com/catalog/suzuki/motorcycle/2000/marauder-vz800/headlamp

Here is the 7" led insert
https://www.amazon.com/gp/product/B076KM96M4/ref=oh_aui_detailpage_o02_s00?ie...

Here is a quick summary of how to make the led insert fit and hold securely int he vz800 headlamp.
1.image 2 part 3 (part#8 will be thrown away) remove from headlamp and place the lamp glass side down, and stomp on it to shatter the glass, and remove chips of glass from outer edge of the lamp ring.
2.Use a circle cutter to cut the a big hole in the metal backing to the appropriate size to allow the led insert to mate flush with the lamp ring
3. Place the led insert in place of where the glass part used to be, it should sit flush over the ring with a few contact points and use a strong adhesive to glue the two rings together.
4. From the led insert package remove the  ring bezel and place that over the led insert, and bend the 3 screw tabs over and around the unit which should hold snug.
5.You will then use steel wire, to wire the 3 tabs together around the backside (make a triangle of steel wire)which should keep the whole package from coming apart.(I will post pics later)
6.Then place the whole package back in the lamp housing as it came apart and plug in the wire to the stock savage harness and its as simple as that.

Here are the pics
(will add more pics of the modified lamp that was cut when I reinstall the light with a better condition vz800 headlamp)

(if the headlamp doesnt look flush its because my headlamp is bent but i have a new one on order)
























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ruckus430
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Re: VZ800 7" Easy Daymaker LED insert
Reply #1 - 01/07/18 at 03:10:21
 
Update:
New VZ800 headlight housing painted in gloss black




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