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Post Subject:

headlight

Reply from: Larry Blanchard
Date: 22 Apr 2008, 18:32
headlight

The low beam on my '83 Suzuki GS450L burned out. OK, no problem, just
replace the headlight. Wrong! Suzuki used this strange headlight with
mounting ears built into the headlight. A standard headlight can't be
used. And of course Suzuki no longer makes the headlight :-(.

So I've got to find a regular 6" headlight nacelle that'll mount to the
450 so I can use regular headlights. I'll make a run to the salvage place
Thursday. I don't expect it'll be a problem, but just in case, I posted
here.

Anyone had to do this? Did you run into any problems? Is there a
specific model that you know works?



Reply from: Mark Olson
Date: 22 Apr 2008, 18:47
Re: headlight

Larry Blanchard wrote:
> The low beam on my '83 Suzuki GS450L burned out. OK, no problem, just
> replace the headlight. Wrong! Suzuki used this strange headlight with
> mounting ears built into the headlight. A standard headlight can't be
> used. And of course Suzuki no longer makes the headlight :-(.
>
> So I've got to find a regular 6" headlight nacelle that'll mount to the
> 450 so I can use regular headlights. I'll make a run to the salvage place
> Thursday. I don't expect it'll be a problem, but just in case, I posted
> here.
>
> Anyone had to do this? Did you run into any problems? Is there a
> specific model that you know works?

Lots of motorcycle replacement headlights are available at mail order places
like Dennis Kirk and JC Whitney, I am sure there are others. JC Whitney
sells halogen replacement units in 5-3/4" and 7" diameter, yours is probably
the 5-3/4" size.

--
'01 SV650SK1 '99 EX250-F13 '98 ZG1000-A13
OMF #7

Reply from: Larry Blanchard
Date: 23 Apr 2008, 06:09
Re: headlight

On Tue, 22 Apr 2008 11:47:38 -0500, Mark Olson wrote:

> Larry Blanchard wrote:
>> The low beam on my '83 Suzuki GS450L burned out. OK, no problem, just
>> replace the headlight. Wrong! Suzuki used this strange headlight with
>> mounting ears built into the headlight. A standard headlight can't be
>> used. And of course Suzuki no longer makes the headlight :-(.
>>
>
> Lots of motorcycle replacement headlights are available at mail order places
> like Dennis Kirk and JC Whitney, I am sure there are others. JC Whitney
> sells halogen replacement units in 5-3/4" and 7" diameter, yours is probably
> the 5-3/4" size.

I guess I wasn't clear enough in my first post. I can't find a headlight
bulb to fit because it's an oddball mount and no longer made. I need to
replace the ENTIRE HEADLIGHT HOUSING with another so that I can use a
standard size/shape headlight bulb like those sold by the aforementioned.

My Yamaha housing is so standard I can even buy bulbs at any auto parts
place - but Suzuki seems to have adopted the Sears model of marketing.

Reply from: Beryl
Date: 23 Apr 2008, 06:57
Re: headlight

Larry Blanchard wrote:
> On Tue, 22 Apr 2008 11:47:38 -0500, Mark Olson wrote:
>
>> Larry Blanchard wrote:
>>> The low beam on my '83 Suzuki GS450L burned out. OK, no problem, just
>>> replace the headlight. Wrong! Suzuki used this strange headlight with
>>> mounting ears built into the headlight. A standard headlight can't be
>>> used. And of course Suzuki no longer makes the headlight :-(.
>>>
>> Lots of motorcycle replacement headlights are available at mail order places
>> like Dennis Kirk and JC Whitney, I am sure there are others. JC Whitney
>> sells halogen replacement units in 5-3/4" and 7" diameter, yours is probably
>> the 5-3/4" size.
>
> I guess I wasn't clear enough in my first post. I can't find a headlight
> bulb to fit because it's an oddball mount and no longer made. I need to
> replace the ENTIRE HEADLIGHT HOUSING with another so that I can use a
> standard size/shape headlight bulb like those sold by the aforementioned.
>
> My Yamaha housing is so standard I can even buy bulbs at any auto parts
> place - but Suzuki seems to have adopted the Sears model of marketing.

* alpha-sports . com /suzuki_parts.htm appears to have the sealed beam
for about $43 + shipping.

Looks like those ears are part of a metal ring around the bulb, which
doesn't seem strange to me. Maybe you could pry the old ring loose and
wrap it around a std. bulb.

Reply from: Dr Ivan D. Reid
Date: 23 Apr 2008, 18:04
Re: headlight

On Tue, 22 Apr 2008 21:57:52 -0700, Beryl <flyingterrapin@chillybits.org>
wrote in <19GdnebTFIqgXJPVnZ2dnUVZ_u2dnZ2d@toastnet>:
> Larry Blanchard wrote:
>> On Tue, 22 Apr 2008 11:47:38 -0500, Mark Olson wrote:

>>> Larry Blanchard wrote:
>>>> The low beam on my '83 Suzuki GS450L burned out. OK, no problem, just
>>>> replace the headlight. Wrong! Suzuki used this strange headlight with
>>>> mounting ears built into the headlight. A standard headlight can't be
>>>> used. And of course Suzuki no longer makes the headlight :-(.

>>> Lots of motorcycle replacement headlights are available at mail order places
>>> like Dennis Kirk and JC Whitney, I am sure there are others. JC Whitney
>>> sells halogen replacement units in 5-3/4" and 7" diameter, yours is probably
>>> the 5-3/4" size.

>> I guess I wasn't clear enough in my first post. I can't find a headlight
>> bulb to fit because it's an oddball mount and no longer made. I need to
>> replace the ENTIRE HEADLIGHT HOUSING with another so that I can use a
>> standard size/shape headlight bulb like those sold by the aforementioned.

>> My Yamaha housing is so standard I can even buy bulbs at any auto parts
>> place - but Suzuki seems to have adopted the Sears model of marketing.

> * alpha-sports . com /suzuki_parts.htm appears to have the sealed beam
> for about $43 + shipping.

> Looks like those ears are part of a metal ring around the bulb, which
> doesn't seem strange to me. Maybe you could pry the old ring loose and
> wrap it around a std. bulb.

I once or twice installed a Cibie' halogen insert into a headlight
shell instead of the Suzuki sealed-beam unit; both were a universal size
and things fitted together with wire "W" clips. I'm sure one was a '77
GD550B; blew both beams on the Hay Plains one Easter and continued on to
the Bathurst races after fitting in a Holden sealed-beam unit. The
advantage of the inserts was that they took a standard halogen bulb and
were MUCH brighter than standard bike lights at the time.

--
Ivan Reid, School of Engineering & Design, _____________ CMS Collaboration,
Brunel University. Ivan.Reid@[brunel.ac.uk|cern.ch] Room 40-1-B12, CERN
GSX600F, RG250WD "You Porsche. Me pass!" DoD #484 JKLO#003, 005
WP7# 3000 LC Unit #2368 (tinlc) UKMC#00009 BOTAFOT#16 UKRMMA#7 (Hon)
KotPT -- "for stupidity above and beyond the call of duty".

Reply from: Larry Blanchard
Date: 23 Apr 2008, 22:42
Re: headlight

On Tue, 22 Apr 2008 21:57:52 -0700, Beryl wrote:

> * alpha-sports . com /suzuki_parts.htm appears to have the sealed beam
> for about $43 + shipping.
>

Thanks for the link. BikeBandit also shows the headlight as available,
but when I called them they said it had been discontinued and was no
longer available. I suspect alpha-sports will give the same response, but
I will call them.

> Looks like those ears are part of a metal ring around the bulb, which
> doesn't seem strange to me. Maybe you could pry the old ring loose and
> wrap it around a std. bulb.

I looked at that and it didn't seem possible, but I'll take another look.

Thanks again.


Reply from: Hank
Date: 23 Apr 2008, 23:54
Re: headlight

Larry
Who told you it is not available? A pimply faced parts kid too
lazy/stupid to look it up? It's gonna be expensive if you find it.
A lot of early models from every mfr use setups like this. Rather than
use a generic sealed beam in a removable ring, they permanently attach the
ring to the bulb like yours and then make it only fit a couple of models.
You may find a ring at a junkyard which will allow you to use a regular
5-3/4" or 7" sealed beam or H4 conversion in your bucket. Harley aftermarket
suppliers sell complete buckets and bulbs - usually chrome - chinese &
cheap. Like 3100265 on this page:
* w w w .jpcycles . com /catalog/2007MetricCatalog/0110.html

I saw all kinds of improvised solutions during my yrs as a parts and
service mgr. Most involved mechanics wire, ductape melts ;-).
Anyway Suzuki (and kaw and yam) tends to obsolete many parts after a
couple of years, so your 25 yr old is definitely due for that. Try going
into a GM dealer and asking for a part for an '83, ha ha!
It is possible for a dealer to have an (some) obsolete part #
"added" back to the pricelist (basically ordered from Japan - sloooow) You
wanna ride it THIS summer right?. Someone probably has it in stock SOMEWHERE
though. If you have any longtime dealers in your area with an experienced
parts man, bringing your old one in early on a saturday morning (when you
aren't holding up other customers) and giving him a chance to search for a
visual match in his stock or going through all of the revised part #'s may
yield results. If you can get a list of all the part #'s between the one on
the fiche (the REAL fiche, not some online parts catalog) and all of the #'s
it changes up to, you can send this list to other dealers by email or fax.
If they don't have to look it up they will be a lot more willing to help.
Try dealers in US AND Canada - they have completely separate parts channels/
warehouses. Try ebay. Lots of people are selling $100 bikes in pcs for $1000
these days.
Hope some of this helps.....
Let us know.
Hank
PS your battery, regulator, and all other lights should be in proper order
to avoid making the new one go poof like the old one................

"Larry Blanchard" <lblanch@fastmail.fm> wrote in message
news:pan.2008.04.23.20.42.13.959365@fastmail.fm...
> On Tue, 22 Apr 2008 21:57:52 -0700, Beryl wrote:
>
>> * alpha-sports . com /suzuki_parts.htm appears to have the sealed beam
>> for about $43 + shipping.
>>
>
> Thanks for the link. BikeBandit also shows the headlight as available,
> but when I called them they said it had been discontinued and was no
> longer available. I suspect alpha-sports will give the same response, but
> I will call them.
>
>> Looks like those ears are part of a metal ring around the bulb, which
>> doesn't seem strange to me. Maybe you could pry the old ring loose and
>> wrap it around a std. bulb.
>
> I looked at that and it didn't seem possible, but I'll take another look.
>
> Thanks again.
>



Reply from: Rob Kleinschmidt
Date: 24 Apr 2008, 00:50
Re: headlight

On Apr 23, 2:54 pm, "Hank" <u...@nbnet.nb.ca> wrote:
> Larry

> A lot of early models from every mfr use setups like this. Rather than
> use a generic sealed beam in a removable ring, they permanently attach the
> ring to the bulb like yours and then make it only fit a couple of models.
> You may find a ring at a junkyard which will allow you to use a regular
> 5-3/4" or 7" sealed beam or H4 conversion in your bucket.

Depending on your degree of confidence, you could always
sacrice the current headlight tosalvage the ring. I've toyed
with the idea a couple times for my own bike.

Reply from: Larry Blanchard
Date: 24 Apr 2008, 18:39
Re: headlight - Thanks, Hank and Beryl

On Wed, 23 Apr 2008 18:54:54 -0300, Hank wrote:

> Who told you it is not available? A pimply faced parts kid too
> lazy/stupid to look it up? It's gonna be expensive if you find it.
> A lot of early models from every mfr use setups like this. Rather than
> use a generic sealed beam in a removable ring, they permanently attach the
> ring to the bulb like yours and then make it only fit a couple of models.
> You may find a ring at a junkyard which will allow you to use a regular
> 5-3/4" or 7" sealed beam or H4 conversion in your bucket. Harley aftermarket
> suppliers sell complete buckets and bulbs - usually chrome - chinese &
> cheap. Like 3100265 on this page:
> * w w w .jpcycles . com /catalog/2007MetricCatalog/0110.html

I called Alpha Sports as suggested by Beryl and they said that yea,
verily, they had my headlight in stock - as well as the side cover I'd
been looking for! I ordered them both. I'm still a little sceptical that
they'll actually show up, but I'm hoping to be pleasantly surprised :-).

The part number Hank suggested has side studs instead of holes, but it
looks like it would work. If the order from Alpha Sports doesn't arrive,
I'll order it. In fact, I'll probably order it anyway, just so I can run
a halogen light (assuming the wattage difference isn't too great - it
wasn't for my old Yamaha SR500).

Many thanks to you both.


Reply from: Who Me?
Date: 23 Apr 2008, 14:46
Re: headlight


"Larry Blanchard" <lblanch@fastmail.fm> wrote

> I guess I wasn't clear enough in my first post. I can't find a headlight
> bulb to fit because it's an oddball mount and no longer made. I need to
> replace the ENTIRE HEADLIGHT HOUSING with another so that I can use a
> standard size/shape headlight bulb like those sold by the aforementioned.
>

No, everything was perfectly clear until you read the replies without first
putting your brain in gear! ;-)

People are TRYING to tell you that entire headlight assemblies ARE
available. Go back and re-read the answers with that thought in mind.



Reply from: Larry Blanchard
Date: 23 Apr 2008, 22:39
Re: headlight

On Wed, 23 Apr 2008 07:46:29 -0500, Who Me? wrote:
>
> People are TRYING to tell you that entire headlight assemblies ARE
> available. Go back and re-read the answers with that thought in mind.

Then I must be missing something. I checked out both Whitney and Kirk.
All I found were extremely expensive HID lights and lights which mounted
via a stud in the base. If these are the ones you meant them I indeed
made an error. If not, I'd appreciate a link to a housing that mounts via
a hole in each side with a hole in the bottom rear for wiring to enter.


Reply from: Rob Kleinschmidt
Date: 23 Apr 2008, 23:36
Re: headlight

On Apr 23, 1:39 pm, Larry Blanchard <lbla...@fastmail.fm> wrote:
> On Wed, 23 Apr 2008 07:46:29 -0500, Who Me? wrote:
>
> > People are TRYING to tell you that entire headlight assemblies ARE
> > available. Go back and re-read the answers with that thought in mind.
>
> Then I must be missing something. I checked out both Whitney and Kirk.
> All I found were extremely expensive HID lights and lights which mounted
> via a stud in the base. If these are the ones you meant them I indeed
> made an error. If not, I'd appreciate a link to a housing that mounts via
> a hole in each side with a hole in the bottom rear for wiring to enter.

Dunno fer sure, but I think I'd look for an H4 conversion kit.
Are you sure that's a 6" not 5 3/4" ?

* store.go-fast-parts . com /lighting-light-conversion-kits.html

Lots of other kits and vendors as well.

Reply from: Elk
Date: 23 Apr 2008, 23:00
Re: headlight

On Apr 23, 7:46 am, "Who Me?" <hitchhi...@dont.panic> wrote:
> "Larry Blanchard" <lbla...@fastmail.fm> wrote
>
> > I guess I wasn't clear enough in my first post. I can't find aheadlight
> > bulb to fit because it's an oddball mount and no longer made. I need to
> > replace the ENTIREHEADLIGHTHOUSING with another so that I can use a
> > standard size/shapeheadlightbulb like those sold by the aforementioned.
>
> No, everything was perfectly clear until you read the replies without first
> putting your brain in gear! ;-)
>
> People are TRYING to tell you that entireheadlightassemblies ARE
> available. Go back and re-read the answers with that thought in mind.

Larry, can you give us the Suzuki part number that you would like to
buy, just
so I can see what exactly it is you are looking for?


Reply from: bob prohaska's usenet account
Date: 25 Apr 2008, 05:08
Re: headlight

Larry Blanchard <lblanch@fastmail.fm> wrote:
> On Tue, 22 Apr 2008 11:47:38 -0500, Mark Olson wrote:
>
>> Larry Blanchard wrote:
>>> The low beam on my '83 Suzuki GS450L burned out. OK, no problem, just
>>> replace the headlight. Wrong! Suzuki used this strange headlight with
>>> mounting ears built into the headlight. A standard headlight can't be
>>> used. And of course Suzuki no longer makes the headlight :-(.
>>>

Is this one of those "fake" sealed beams with a stamped reflector that
doubles as a mounting bracket for a bulb that's soldered into it with a
glass lens crimped on the front?

If so, I'd suggest breaking out the glass, cutting out the bulb area and
using it as a base for a similar size standard headlamp. That will preserve
the mounting and adjustment mechanisms. It's not hard to do provided the
old light is the same size or slightly larger than a modern replacement.
It might be a little extra work to find room for the connector, which is
apt to have more rear projection that the original wiring.

Good luck,

bob prohaska





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Thread:
    Beryl
     Dr Ivan D. Reid
     Larry Blanchard
      Hank
       Rob Kleinschmidt
       Larry Blanchard
    Who Me?
     Larry Blanchard
      Rob Kleinschmidt
     Elk