This mod was a lot of work. It could easily be argued that it`s not necessary, and that riding at night should be avoided anyway.
I say that riding at night is pretty much inevitable, and these puppies turn night into day. I`m relieved I put them on, I love the look, and the fact the setup is a one off.
I was on a bike holiday in Cambodia over Christmas and New Years of 2007/8, and hired a Honda XR250 Baja. I loved the lights, and set about searching for a pair for sale. I tracked down a quality French chap running a bike hire/tour business, he sourced a few pairs of Baja lights, and sold me a set at an almost fair price.
The hardest bit of the install was getting everything to clear the big Acerbis 22l tank.
The only worry I have is that the lights are stamped 35W, which I assume refers to the bulb wattage. I put 60W Xenon bulbs in, but all OK so far. No sign of melting.
Installation went like this;
- Remove all the existing lighting parts
- Remove headlight mount bracket
- Make replacement plate to secure clocks
- Bolt up lights to triple clamp
- Turn bars and mark where the light frame fouls
- Remove great chunk of the light frame so it clears the tank
- Weld thick ali gussetts to the light frame to strengthen
- Mark where brake line fouls light frame
- Remove offending part of frame
- Weld thick ali gussetts to the light frame to strengthen
- Make and weld on tabs for 2 relays to bolt up
- Make and weld plate to keep water spray away from electrics
- Grind and polish everything back flush
- Clean and powdercoat matt black
- Solder and crimp a load of wiring between H4 bulbs and relays
- Run new wiring from battery, chop into existing lighting wiring
- Connect it all, and it`s good to go!
