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The TTR250 FAQ web pages -> TTR250 -> Modifications -> Headlight Upgrade on '93 OE
Post Info TOPIC: Headlight Upgrade on '93 OE
stringy


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Headlight Upgrade on '93 OE
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I thought I'd share my headlight upgrade as it has enabled me to ride safely at night around the dark lanes of Dartmoor and surrounding area. I didn't think to take photos of each step but hopefully this will help anyone who is interested. Everything was sourced from Ebay.

I decided that I wanted a round headlight in the style of a Raid. So, the bracket was sourced by searching for Headlight Crash Protector Guard Upper Fairing Stay Bracket For Yamaha TTR250  . This bolted straight on and has the advantage of the tabs needed to fit the screen. The only slight negatives with this bracket are that it is not particularly lightweight and that surface rust appeared with the morning dew! Probably repainting or ideally powder coating would solve the rust issue. 

The screen I searched with Motorcycle ABS Black Sports Windscreen Windshields For Yamaha TTR250 TTR 250 TTR . This needed a bit of judicious sanding to get it to fit but I'm pleased with the results.

Now the headlamp was the tricky bit to source. The closest I could find that was relatively cheap is a pattern headlight unit for an RD350LC. Complete Headlight Round For Yamaha RD250, RD350LC 8" . The housing does need a lot of patience, cups of tea and a I used a dremel. A lot of cutting and shaping later and it fits quite well. It required a lot of material to be removed particularly from the rear and also and area at the top underneath the clocks. Pay attention to the the 'fin' on the right hand side as this can foul the cover for the steering lock on a full lock right turn. I had to mess around with the mounting tabs, bolt lengths and spacers to fit the unit in the bracket centrally and to adjust the beam. Fine adjustment can be made using the built adjuster. This unit will take a 60watt H4 bulb no problem and the generator hasn't struggled to keep the battery charged. Rather than butcher the original loom, I used spade connectors on the fittings included with the headlight, some insulting tape and a zip tie to keep it together. So far, and mostly riding in the rain I haven't had any problems at all. This also has the advantage that I can return the bike to standard spec very easily. The main beam is great and dipped is sufficient i.e. not scary but could be a better spread of light. The weight increase is  just noticeable on rough muddy trails but not a problem.

I will shortly remove it all to powder coat the bracket, tidy up the trimmed edges of the housing and sort a proper connector as a long term solution. Hopefully this will help you if you need better lighting and like the idea of a round headlight.

Happy fettling.

 

 



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comeragh


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Looks great .Always liked the classic round headlight look.

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ttr steve


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Good work Simon

I know a lot of TTR owners will be grateful of this info, as the raid headlight is so much better if needed at night

Any chance you could add the links for the screen and the surround, was they from aliexpress?

Good news that the headlight from another bike fits smile



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jasparach


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Any chance you could add the links for the screen and the surround, was they from aliexpress?

I too would be interested in the bracket to hold the light. I have a headlight from a Yamaha 535 Virago fitted to my 96 OE. It takes the brighter bulb and is big improvement over the original.

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1996 TTR 250 OE, 1996 YAMAHA WR 200, 1990 YAMAHA FZR 1000,2001 HONDA DEAUVILLE 650, 2005 TTR 250, 1998 Honda CR125R( in pieces) 1994 Kasawaski KX 250.
stringy


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Thank you. I rather like the look of the bike now. Must be my age!



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stringy


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I tried to do the links but for some reason they wouldn't work. If you do a search on Ebay for each item using the descriptions I have highlighted in bold, that should get you to the correct listing.



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TTRfan


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Hopefully these are the correct links?

https://www.ebay.co.uk/itm/Headlight-Crash-Protector-Guard-Upper-Fairing-Stay-Bracket-For-Yamaha-TTR250/293145355994?hash=item4440d326da:g:KQgAAOSw6fVdIuzX

https://www.ebay.co.uk/itm/Motorcycle-ABS-Black-Sports-Windscreen-Windshields-For-Yamaha-TTR250-TTR-250-TTR/293371636481?hash=item444e4feb01:g:wM8AAOSwnYVd8KaY

https://www.ebay.co.uk/itm/Complete-Headlight-Round-For-Yamaha-RD250-RD350LC-8-Each/362249774649?hash=item5457c4e639:g:vF0AAOSwn2JdC4I1

 



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ttr steve


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Nice work Brismile



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JOHNYBOY


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but how does the headlight mount on the ttr

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dlee22


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The frame mounts using the top yokes pinch bolts from memory

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Thanks

Daniel Lee
JOHNYBOY


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any pics please

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stringy


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Thanks for your help with the links Brian. The headlight bracket does bolt straight onto the top yolk using the standard pinch bolts and the headlight then bolts into the bracket after a fair amount of 'surgery'. Like I said, it takes patience and many cups of tea but really isn't very technical. I'll possibly strip it back a little and take some more pics.smile



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jasparach


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Is there any part number for a Raid headlight does anyone know?

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TTRfan


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jasparach wrote:

Is there any part number for a Raid headlight does anyone know?

 Any good John?  https://www.megazip.net/zapchasti-dlya-motocyklov/yamaha/tt250r-14507/tt250r-tt-r-raid-28136/4wa1-768548/headlights-2-13364876 



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JOHNYBOY


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hi brian i mean how does the headlight mount on the bike please john


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jasparach


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TTRfan wrote:
jasparach wrote:

Is there any part number for a Raid headlight does anyone know?

 Any good John?  https://www.megazip.net/zapchasti-dlya-motocyklov/yamaha/tt250r-14507/tt250r-tt-r-raid-28136/4wa1-768548/headlights-2-13364876 

 Brilliant find Brian, just what i was after. Many thanks for that. 



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1996 TTR 250 OE, 1996 YAMAHA WR 200, 1990 YAMAHA FZR 1000,2001 HONDA DEAUVILLE 650, 2005 TTR 250, 1998 Honda CR125R( in pieces) 1994 Kasawaski KX 250.
jasparach


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Cross referencing the numbers in the link you sent me Brian with numbers i searched on for a 1995 Yamaha Virago 535 show the actual part number to be the same but obviously the model prefix is specific to the particular bike that one is searching on. I will investigate some more on it but initial searching shows the lens assembly,retaining ring, headlight rim and lamp body to have the same part number.

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1996 TTR 250 OE, 1996 YAMAHA WR 200, 1990 YAMAHA FZR 1000,2001 HONDA DEAUVILLE 650, 2005 TTR 250, 1998 Honda CR125R( in pieces) 1994 Kasawaski KX 250.
jasparach


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JOHNYBOY wrote:

hi brian i mean how does the headlight mount on the bike please john

 The light bracket bolts to the fork pinch bolts John and the headlight is retained on the light bracket by 2 bolts into the side of the light through 2 plates on the bracket and the lower legs of the bracket rest against the fork tubes.



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JOHNYBOY


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many thanks do you have any pictures please john

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Cubber


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They are at the top of this thread, John.

I'll turn them to their proper orientation for you and put them below

1.JPG

2.JPG

3.JPG

4.JPG

5.JPG

 

There, can you see them now?

Martyn



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ttr steve


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Good work martyn, you beat me to it smile



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JOHNYBOY


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thank you gentlemen i grasp it now you have got to have the raid bracket john

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