LED Headlight Install (7" Round)

[EdChen]

I've been looking at LED headlight options and wanted to keep it DOT legal. I found the Trucklite 27270C: http://www.truck-lite.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10001&productId=92025

I bought a used on eBay, but it obviously doesn't fit easily. The existing GS500 headlight has the mounting points and adjustment screw bracket attached to the back of the lens reflector. I bought a lens/bucket set from an '89 GS to use so that I can keep riding the bike while working on it.



So far, I removed the trim ring around the lens/reflector assembly and got that mounted on the new LED headlamp. You can see that a good deal of headlamp sticks out past the trim ring.



More pictures: http://imgur.com/a/B043S/all

I'm debating a couple options:

1) cut/pry off the mounting tabs then epoxy them to the LED headlamp.

2) mill a round trim ring out of some thick aluminum plate that I can attach the headlamp to, then screw or braze some brackets on in place of the 3 mounting tabs.

Does anyone have any other thoughts or suggestions?

[Jensen567]

First let me say, THANK YOU for not blinding the crap out of everyone else on the road with cheap LED "retrofits"

I just went through this same thing on my new bike (I went with the Peterson vs the Trucklite because I liked that the connector was integrated into the housing vs a pigtail, same idea though).  In the end, I decided that the amount of time I was going to spend custom making something to fit it into a stock housing was not worth it, and decided to go with an Emgo headlight bucket off of Amazon.  Slightly different look than stock, but will do the job, and as looks are subjective, you may even like it better.  You need to bend the positioning tab in order to get the light in, but once it is in the clips hold it securely and you can bend it back to hold position.

I went with the black one (it is flat black, not glossy black as the description says, I prefer this anyway), but they also have carbon and chrome.

http://www.amazon.com/Emgo-Lucas-Style-Headlight-Shells/dp/B00M9MXLA8/ref=sr_1_4?ie=UTF8&qid=1442955505&sr=8-4&keywords=emgo+headlight

http://www.amazon.com/Emgo-Lucas-Style-Headlight-Shells/dp/B00M9MXIBA/ref=pd_sim_sbs_263_15?ie=UTF8&refRID=1HA9HJ7WM6GHJSD89RP3

http://www.amazon.com/Emgo-Lucas-Style-Headlight-Shells/dp/B00M9MXNAQ/ref=pd_sim_sbs_263_9?ie=UTF8&refRID=1HA9HJ7WM6GHJSD89RP3

Here is a photo of mine with the Peterson LED installed.

[EdChen]

Thanks for the info! I think that's a very good backup option. I don't think I might now those buckets look, might work well for me actually. Did those buckets bolt right up to the existing headlight mounts?

This one appears to be fairly stock looking, and has 8" spaced tabs, which from my quick measurement, are pretty close to stock: http://www.amazon.com/Emgo-Headlight-Assembly-Chrome-66-65040/dp/B00A3HOH6I/ref=sr_1_6?s=automotive&ie=UTF8&qid=1442957902&sr=1-6&keywords=emgo+7%22+headlight

btw, your pictures don't seem to show up for me. I'd love to see a before and after shot of the beam, plus it installed on the bike.

[Jensen567]

Unfortunately I can't comment on if it fits the stock bracket without modification yet, as my bike is a 2007 F and my headlight brackets haven't shown up yet.  However I can tell you that the holes are 6-7/8" apart, so you can compare that to stock.  They are side mount holes like stock though, I am assuming spacing is fairly standard throughout the industry, but I could be dead wrong on that.  Didn't really check TBH because I figure I can always cut and bend new triangles fairly quickly to compensate.

I will look into why the pictures don't show up for you, it must have to do with sharing options where they are hosted as they show up for me.  I don't have a stock headlight to compare beams with, but I do have a standard H6024 sealed beam I can compare it with.  I will try to get shots of that this week.  I can tell you though that the Peterson LED has a beautiful pattern and cutoff.

EDIT:  I changed my links above, let me know if that fixed it.

[EdChen]

Loading perfectly for me now! Thanks!

Just saw your other post with more pics of the bike. looking good!