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The TTR250 FAQ web pages -> TTR250 -> Repair and maintenance "stickies" -> Headlight Repair
Post Info TOPIC: Headlight Repair
TDVT


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Headlight Repair
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Having just gotten my TTR, I am going through repairing the odds & ends that are damaged or broken, one of which was the headlight/plate. It had a broken tab on one side, presumably from a spill & was bouncing around pretty good when I got it.

Instead of repairing the one tab, I decided to remove the other plasic tab & fabricate a bracket to span the two upper mounting points & then mount the headlight to that. It's pretty self-explanitory from the pics. Cleaned up the remains of the plastic tabs with a rotary burr.

I also found out from my inspection station that I will have to install a speedo for my inspection (new rule for Vermont) so I made the bracket arms 1" (25mm) longer so I would have more space to mount a Trail Tech meter behind the headlight/plate. The US-spec TTRs only have a trip odo which I'll probably remove since the Trail Tech has that feature.

I didn't fabricate a new bottom bracket (yet) but substituted a longer bolt with a 1" long tube spacer to keep things relatively aligned.

Way more solid now & a little more room for my street-legal adaptation.

Headlight1.jpg

Lightbracket1.jpgLightbracket2.jpg



-- Edited by TDVT on Wednesday 27th of June 2012 01:50:30 AM

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LRJ


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Good idea! Good fix. If you would really prefer a mechanical speedometer (In case you didn't know this, already) the speedo from an XT225 hooks up to the cable for your stock tripometer and works quite well. In fact, it looks like the same speedo is stock on the British imports.

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KNjonjo


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This is a brilliant solution. On my 1993 OE, I fitted the headlight surround and assembly from the Honda XL200 (Brazilian made and sold new here in Kenya) so I can use regular H4 bulbs up to 100W but I'm not happy with the current mount. It looks like your idea will be perfect.

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TTRfan


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What a great idea. My solution was a lot more difficult and probably a lot weaker - see http://ttr250.activeboard.com/t44860901/repairing-broken-headlight-supports/

I will add this thread to the growing list of "stickies" smile

Brian

PS Thanks for the info on the XT speedo LRJ!



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TDVT


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Glad it might be of help!

The stock I used was 1/8" X 1" aluminum flat purchased at a home center. I bent an arc by hand the conform to the headlight, then bent the ends by hand in a vise. Drill 4 holes & it's done.

Thanks for the info on the speedo. The inspection guy/shop actually had a mechanical speedo on hand but I'm eyeing the Trail Tech model with a tach (also has air temp, time-of-day, engine temp, & more).

 

Ted



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