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The TTR250 FAQ web pages -> TTR250 -> Modifications -> Replacing the glass headlight unit on a later model European blue TTR250
Post Info TOPIC: Replacing the glass headlight unit on a later model European blue TTR250
TTRfan


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Replacing the glass headlight unit on a later model European blue TTR250
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I have a couple of headlight units from circa 2004 models that need to be replaced.

The example below is of one where the original Yamaha glass unit was smashed by a mate roosting me in a stony lane no . Because of the high cost of the Yamaha unit (#5CH-H4310-00 - currently over £88 retail) I replaced it with a KTM unit that fitted straight in. However, being greedy for lumens, I put in a big halogen bulb that, over time, melted the plastic lens disbelief

Headlight_mod 008.jpg

I wasn't able to find the exact same unit so bought the nearest I could find which costs just under £30 retail. I have gone for a plastic unit again as I will be using it on a trail bike where a glass unit is vulnerable (at least with some of my mates it is anyways!) but will be a bit more careful with the size of bulb this time! It's another KTM unit - part number 50211610000.

Headlight_mod 001.jpg

I only realised when I opened the box that it wasn't going to be a straightforward fit as per the previous KTM unit but at least it fits the hole nicely biggrin

Headlight_mod 003.jpg

But, this one has tabs at the side that foul the TTR headlight mask.

Headlight_mod 004.jpg

Nothing that an attack of the Dremels can't sort out though. As a side note, I found some excellent little cutting discs for the Dremel as shown below. It is amazing what they can cut through!

Headlight_mod 005.jpg

Once the tabs were removed the unit sits down nicely into the TTR mask.

Headlight_mod 006.jpg

I now have to devise a simple pair of brackets to hold the light unit into the mask that preferably allow the adjuster to work. Any thoughts folks?

Brian

 



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barra8


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This would be my solution to it (mainly because its easy & light).....

I used black pen to show the slot in the bracket. To adjust push the bracket in & tighten so it holds it in. You should still be able to use the bottom adjuster (100% adjustment if the bracket is brazed to the headlight.)

You could braze it to the headlight aswell if you wanted to get carried away.

Hope you don't mind Brian but i stole your pic to show you better....

Maybe someone has a better one as this only took a few minutes to think of. confuse

......................

Jarrah.

 



-- Edited by barra8 on Thursday 3rd of January 2013 03:06:26 AM

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smithy


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i think the headlight out of dt125re or dt125sm might fit as the headlight cowl looks very similar to a ttr250



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TTRfan


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smithy wrote:

i think the headlight out of dt125re or dt125sm might fit as the headlight cowl looks very similar to a ttr250

 Thanks Smithy - I will rember that for the next time. Meanwhile, anyone tried that?

 

barra8 wrote:

This would be my solution to it (mainly because its easy & light).....

I used black pen to show the slot in the bracket. To adjust push the bracket in & tighten so it holds it in. You should still be able to use the bottom adjuster (100% adjustment if the bracket is brazed to the headlight.)

You could braze it to the headlight as well if you wanted to get carried away.

Maybe someone has a better one as this only took a few minutes to think of. confuse

......................

Jarrah.

Thanks for your input Jarrah - that is certainly the way I am thinking. I am not able to braze as the headlight unit is all plastic.

I am not going to rush this in case I miss something obvious but will be back soon wink

Brian



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barra8


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Good on Brian.....You have the templates ......now to make them out of alloy :) jks. wink

It does'nt have to hold alot of weight & should last awhile. In the meantime.......alloy brackets??? smile 

Oh .......thinking about it that plastic is thicker than it looks in the pic....but will it melt???

I'd just keep an eye on it.

I was thinking thick rubber/leather?/conveyor belt? A peice cut out of an empty can or tin  bent flat (after drilling holes) as it won't burn so easy????

Of course it's ''totally'' up to you what you do with your bike & this is only suggestions. smile

............................

Jarrah.


 



-- Edited by barra8 on Sunday 6th of January 2013 09:31:28 PM

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TTRfan


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The simplest solutions are usually the best and you can't get much simpler than mine wink

Four tabs cut from a blue plastic oil drum and the retaining nuts and bolts out of an old headlight unit. 

Headlight_mod 009.jpg

I cut one of each pair longer than the other to help put pressure on the headlight unit.

Headlight_mod 011.jpg

Headlight_mod 013.jpg

I can vouch that this simple system holds the headlight in very firmly to the extent that I will have to rethink if I need to install the adjuster!

Headlight_mod 010.jpg

I am going to try the light to check the throw of the beam before doing any more but the job is 95% complete. Just the connector to make up and possibly the adjuster to install biggrin

A cheap(er) alternative to the expensive OEM Yamaha part!

Brian



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TTRfan


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Thanks for the ideas Jarrah but I am going to fit it as it is and see how it goes. The idea of using plastic is that it is flexible but not too much so that it will let the light unit move. I don't think that part of the unit will get that hot but will check it out before the road test.

I will report back wink



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barra8


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TTRfan wrote:

Thanks for the ideas Jarrah but I am going to fit it as it is and see how it goes. The idea of using plastic is that it is flexible but not too much so that it will let the light unit move. I don't think that part of the unit will get that hot but will check it out before the road test.

I will report back wink

 I was thinking that myself.....Just thought i'd make sure you have that in mind wink

Hope it works for you

................

Jarrah.



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mossproof


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Has anyone seen a Baja Designs enduro headlight in use? (Pt No BD 60-0002) They look a similar size to the TTR light, in glass and with seemingly good optical quality. My OE has a UFO rectangular lens light which is downright dangerous at night, as is my mate's original OE spec one. Like the shape, which is why I haven't gone Raid style, but I like to see where I'm going in the dark!
Simon.

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TTRfan


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mossproof wrote:

Has anyone seen a Baja Designs enduro headlight in use? (Pt No BD 60-0002) They look a similar size to the TTR light, in glass and with seemingly good optical quality. My OE has a UFO rectangular lens light which is downright dangerous at night, as is my mate's original OE spec one. Like the shape, which is why I haven't gone Raid style, but I like to see where I'm going in the dark!
Simon.

 Linky here and here

Looks good Simon. Might be worth asking the dimensions of the light unit to see if it would fit the standard TTR headlight mask wink

Brian



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mossproof


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Thanks Brian, haven't worked out how to do that link thingy yet!

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Size of the headlight lens is 5 1/4" by 3 5/8" according to the reply I got from Baja Designs this morning. They'll ship to the uk, but I might get one sent to a mate who ships other stuff over here regularly. They use this lens (glass) with some quite beefy bulbs according to their website, so shouldn't melt! I just wonder if the optical quality is good. Only one way to find out...
I've seen replaceable perspex headlight lens covers somewhere - just a rectangle that sits in 2 runners. Slide in, slide out. Better than mesh and easy to replace. Another winter evening project...
Will post when I've got some results.
Simon.

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TTRfan


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Well volunteered Simon! biggrin



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