Converting GS500F to E and moutning Stock F Headlight **HELP**

[Faint]

I'm in the middle of converting my 2005 F to an E but I'm remounting my F headlight... I'm sort of stuck now.

I've made it this far:


Here is my stock headlight ready to be mounted:


I managed to find some extra bolts that fit my headlight and mounting brackets I bought:


The problem is I can't for the life of me get my mounts to fit. They wont screw around my forks and I'm not even sure how far I need to bend them or if they're even long enough,

Here's what I bought:


Here's how I've bent them so far:


I think this is how they're supposed to fit:



Any advice? I'm short on tools so I'm having to bend by hand + Plyers... Can someone tell me exactly how I need to get this thing mounted?

Also, on a side note, how do I hide my horn that's sticking out?


Sorry if the pics are small... I'm using my cell phone. I may be able to get some bigger ones if you really need them.

I have class at 7pm and I need my bike if at all possible. It's 2:09pm now. Any help is greatly appreciated!!!

Thanks!

[JHoffy8]

pics didnt work... or could be my comp at school

[mach1]

I had those same mount and they suck. I had them on for a week and the small wrap around piece skiped our of it slot almost everyday I don't recomend using them. If you keep them than just keep trying they may not be long enough bent but if you straighten them and drill and tap the side of your headlight that may work but use helicoils when drilling and taping plastic.

[Faint]

I had those same mount and they suck. I had them on for a week and the small wrap around piece skiped our of it slot almost everyday I don't recomend using them. If you keep them than just keep trying they may not be long enough bent but if you straighten them and drill and tap the side of your headlight that may work but use helicoils when drilling and taping plastic.

Could you link me to a mount worth buying? I'm poor, keep that in mind and I don't own a drill...

Thanks

[Faint]

... My headlight is too wide for the brackets to reach. How the hell do I get this thing mounted. Please help!

I'm begging :/

[lawman]

... My headlight is too wide for the brackets to reach. How the hell do I get this thing mounted. Please help!

I'm begging :/

"fitty mahl an awr taype" ... for the time being.

Perhaps you're finding out why we rarely see this conversion...

too wide...  What if you got a sheet of steel with holes in it, bolted the HL onto that, and bolted that onto the brackets?  Or got another type of bracket, even, and bolted the HL onto those and bolted those onto the brackets.

[Faint]

I could't get the headlight on so I zip tied the hell out of it. I'm now looking for a round headlight so I can still be naked with a working headlight...

[fred]

I could't get the headlight on so I zip tied the hell out of it. I'm now looking for a round headlight so I can still be naked with a working headlight...

You really only need the headlight brackets from a naked GS. Once you have the bracket, just go find whatever 7" round headlight you like at a bike junk yard or on ebay or whatever. There are lots that will fit... My headlight was cheap at the local motorcycle salvage yard and came off a '70's Yamaha. I just went to the place and they let me dig through their giant box of headlights until I found something I liked... There is also a guy on the forum who makes a bracket specifically for mounting the F headlight to a naked GS as I recall. You might be able to find that guy with a search and save some money by only buying the bracket... You could also sell your old headlight and faring to fun the purchase of whatever headlight you like and still come out ahead...

[Danny500]

Do you have any better pics of what you did???

For one you bent those brackets way too far. Here's what mine looks like:





They should be at  no more than a 45 and you need to drill holes through the angled part of the headlight mount and cut off that flat piece...

Like this:



Then just get a couple of 1 1/2 inch long bolts with lock washers and bolt them in. I recommend using 1/2 inch bolts...

Also, on your mounts, use loc-tite and a lock washer on the screws... don't over-tighten them as you will pull the tab out of the ring. Just snug them up and let them cure.

[JHoffy8]

I have 2 left fork tube brackets if you end up needing them let me know. One for you and your brother! O and we have the same bike, nice choice.

[Faint]

Do you have any better pics of what you did???

For one you bent those brackets way too far. Here's what mine looks like:





They should be at  no more than a 45 and you need to drill holes through the angled part of the headlight mount and cut off that flat piece...

Like this:



Then just get a couple of 1 1/2 inch long bolts with lock washers and bolt them in. I recommend using 1/2 inch bolts...

Also, on your mounts, use loc-tite and a lock washer on the screws... don't over-tighten them as you will pull the tab out of the ring. Just snug them up and let them cure.

This helps a lot.

I'll get some new pics when I have time (work and school, ugh ><)

But essentially, I need to break off all of the old tabs that used to be on the headlight then re drill a hole through which tab exactly?

It also looks like I mounted my brackets upside down and I'll have to re bend them to get them to fit again.

Could you take a really close picture of where exactly you put the bolts through the headlight to mount it? I'm really hesitant when it comes to making my own holes through plastic especially since I don't own a drill....

Thanks everyone!

Also, I may get back to you on those fork brackets, Jhoffy... We'll see how the re bend goes... lol

[mach1]

The stock tube brackets that go on the gse forks are good and sturdy you would just need some tabs that go to the brackets and the headlight. I see them on ebay often but they go quick.

[Danny500]

A. Install light posts aiming up as far down on the triple trees as possible (on top of the lower tree).

B. Bend the ENDS of the tabs to about a 45 degree angle as viewed here (looking down) on the forks.

C. Cut off all the tabs in red.... when you get to the LARGE tabs, cut ONLY the flat part off BEFORE the angle... this angled piece is your new mounting position.

D. Drill a hole (1/2 inch) in the tab, one on each side...

(Not shown.) Mount it!!!

Dan

[erbilabuc]

as long as you get the mounts to be 37mm or bigger you will be fine. Search my posts and you will find the part numbers that you need from dennis kirk. Buy the mounts that I posted as they are the ones I used and they were only 11$

[Faint]

A. Install light posts aiming up as far down on the triple trees as possible (on top of the lower tree).

B. Bend the ENDS of the tabs to about a 45 degree angle as viewed here (looking down) on the forks.

C. Cut off all the tabs in red.... when you get to the LARGE tabs, cut ONLY the flat part off BEFORE the angle... this angled piece is your new mounting position.

D. Drill a hole (1/2 inch) in the tab, one on each side...

(Not shown.) Mount it!!!

Dan

I completed this yesterday.

I used a kitchen knife to cut the plastic off because I lacked a saw and I had to bend the hell out of the "Universal" mounts to get them to fit.




My only question now is how can I have straight perpendicular turn signals and how do you hide the turn signal wires and horn... and if there's any way to make sure my headlight doesn't vibrate out of alignment with the road.

I'll try to get some new pictures of it mounted on my lunch break.

Thanks!

[Danny500]

There are a couple things you can do to prevent vibration... however, they're kind of moot once I tell you this next thing.

For all the wires, tape them together and tuck them between the trees behind the light... they will actually support the back of the light from too much movement. Also, it looks as though you mounted the mounts on the wrong sides... you might want to swap them... could just be the angle of the pic.

Where is your horn? Mine is mounted up on the frame under the tank, waaaayyy out of the way, might want to do that.

As for the blinkers, use large sheet metal washers and mount them through the middle hole on the brackets. Having them angled OUT a bit isn't too bad, but if you want to get fancy just spend a little time bending the brackets around to get the flattest mounting position.

Looks good so far! Damn good work for a kitchen knife! Lol. 

OH, also, use a lock washer on the underside of the BOLT head for the headlight and also use a tooth-lock washer (the kind that's like a gear looking thing) for the back side FIRST, before you put a regular washer, a lock washer, loctite and a nut.

It will kind of keep everything from backing out and prevent the headlight from tilting up/down ... but like I said, the wires take care of most of that.

[Faint]

There are a couple things you can do to prevent vibration... however, they're kind of moot once I tell you this next thing.

For all the wires, tape them together and tuck them between the trees behind the light... they will actually support the back of the light from too much movement. Also, it looks as though you mounted the mounts on the wrong sides... you might want to swap them... could just be the angle of the pic.

Where is your horn? Mine is mounted up on the frame under the tank, waaaayyy out of the way, might want to do that.

As for the blinkers, use large sheet metal washers and mount them through the middle hole on the brackets. Having them angled OUT a bit isn't too bad, but if you want to get fancy just spend a little time bending the brackets around to get the flattest mounting position.

Looks good so far! Damn good work for a kitchen knife! Lol. 

OH, also, use a lock washer on the underside of the BOLT head for the headlight and also use a tooth-lock washer (the kind that's like a gear looking thing) for the back side FIRST, before you put a regular washer, a lock washer, loctite and a nut.

It will kind of keep everything from backing out and prevent the headlight from tilting up/down ... but like I said, the wires take care of most of that.

I was going off this picture when I mounted the headlight so the brackets are angled down...



You think I should switch them and angle it up? I'm scared with all the fidgeting I'll brake the plastic I drilled through.

I'll definitely try the wire method to secure the headlight from moving although one problem I did notice is that every time I hit a speed bump my headlight tilts up and I have to tilt it back down.

There's also a "knock" whenever I hit the speed bump but I can't tell if it's just my shocks or if my headlight is actually hitting something... And my horn is currently stuck on the left front of my bike. I'll up a pic in a minute.

[cafeboy]

Man I freaking love this head light mod 

[Faint]

Here's a pic of my Horn and side of the headlight. Does it look like I have enough clearance or am I hitting the top of my tire when I drive over speed bumps?



Here's a few more pics of the "completed" project.

[cafeboy]

I like it.