Round single headlight replacement? - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 15 (permalink) Old 1-24-2020, 3:49 AM Thread Starter
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Round single headlight replacement?

So my bike was dropped pretty bad at some point before I bought it and replaced with a crappy aftermarket fairing with a pretty bad rattle can job, so I've decided to go the route of a semi-streetfighter build, starting with a round headlight.

Anyone have any suggestions on specific lights or things to look out for when picking out a light? Tips on type of light, any potential wiring challenges? I'm not completely inept when it comes to electronics, but i'm obv not familiar with the bike's wiring.

Thanks!

the name's rex. happy to be here.
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post #2 of 15 (permalink) Old 1-24-2020, 8:37 AM
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If yo take out the fairing, likely will need to take out the fairing stay too... and with it goes the indicators. So you will need to replace the instrument cluster (some people goes with trail tech, vapor... or something like that).

Also, he ligth will need brakets to clamp at the forks.

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post #3 of 15 (permalink) Old 1-24-2020, 3:23 PM
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I have run an older Vulcan headlamp. The older Kawasaki Vulcan headlamps use the same bulb as the stock EX500 bulb, so no need to alter the wiring.

Far as mounting, there are plenty of different ways. When I mounted it on a gen1, I used some generic aftermarket universal headlamp mounts and then chopped and welded the instrument cluster mounts to the headlamp mount and called it a day. You can also try looking for the stock headlamp mounts off any older cruiser. Many utilized a tab coming off a tube which was sandwiched between the upper and lower triples, making it relatively universal. The advantage with using older OEM parts sourced from different models is the quality will be much higher than most universal aftermarket stuff, not to mentioned cheaper.

Mounting up either the original turn signals, older cruiser/naked turn signals or aftermarket universal stuff shouldn't be too hard. Be sure to get 3 wire signals if you want to keep the running light function. Also, you get what you pay far, beware of cheap-o Chinesium stuff off Amazon or Ebay.

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post #4 of 15 (permalink) Old 1-24-2020, 7:33 PM
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Streetfighters need round headlights? You can scrap the bodywork and still use the stock headlight, can't you? There is some beautification needed if one minds, but the cover is not structural.


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post #5 of 15 (permalink) Old 1-24-2020, 8:34 PM Thread Starter
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Originally Posted by Saabnut View Post
I have run an older Vulcan headlamp. The older Kawasaki Vulcan headlamps use the same bulb as the stock EX500 bulb, so no need to alter the wiring.
Appreciate the advice! I'd definitely look for an old Vulcan light. I'll figure something out like that with the instrument cluster, shouldn't be to tough to remount it somewhere.

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post #6 of 15 (permalink) Old 1-24-2020, 8:36 PM Thread Starter
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Originally Posted by happycommuter View Post
Streetfighters need round headlights? You can scrap the bodywork and still use the stock headlight, can't you? There is some beautification needed if one minds, but the cover is not structural.
Great looking bike! Might just do that in the meantime while I get all the parts together. I don't think street fighters need much to qualify as that, but I've got a specific look i want in mind haha.

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post #7 of 15 (permalink) Old 1-26-2020, 2:01 PM
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Check out the thread on my bike (link in signature), I have a round headlight on there that I got from 4into1.com. Inexpensive and so far a great headlight.

Paul

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post #8 of 15 (permalink) Old 1-27-2020, 4:03 AM Thread Starter
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Check out the thread on my bike (link in signature), I have a round headlight on there that I got from 4into1.com. Inexpensive and so far a great headlight.
Looked through the thread, fantastic looking bike! Appreciate the recommendation/link.

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post #9 of 15 (permalink) Old 1-27-2020, 4:07 AM Thread Starter
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Originally Posted by happycommuter View Post
Streetfighters need round headlights? You can scrap the bodywork and still use the stock headlight, can't you? There is some beautification needed if one minds, but the cover is not structural.
Also, I discovered that on the 2nd gens, the headlight is mounted to the fairing and not the fairing stay bracket, so I had to come up with something a little more.. creative *cough*temporaryzipties*cough* to put the headlight back on.
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post #10 of 15 (permalink) Old 1-27-2020, 2:10 PM
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Quote:
Originally Posted by littleprince View Post
Also, I discovered that on the 2nd gens, the headlight is mounted to the fairing and not the fairing stay bracket, so I had to come up with something a little more.. creative *cough*temporaryzipties*cough* to put the headlight back on.
You have discovered the single thing I hate most about 2nd gens. The tabs on the fairing and headlamp both like to snap off when the bike is dropped. As you so mentioned, the headlamp can't be properly mounted without the upper fairing in place. Kawasaki had it right with the gen1's with the headlamp mounted directly to the fairing stay and did so without using flimsy tabs on the housing. It's extremely difficult to damage those headlamps.

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post #11 of 15 (permalink) Old 1-28-2020, 7:14 PM
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Quote:
Originally Posted by happycommuter View Post
Streetfighters need round headlights? You can scrap the bodywork and still use the stock headlight, can't you? There is some beautification needed if one minds, but the cover is not structural.

My headlight requires the fairing structure to be mounted to... How do you remount your light?? The previous owner of mind really jacked up the fairing...
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post #12 of 15 (permalink) Old 1-29-2020, 1:55 AM Thread Starter
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Originally Posted by tesuzuki2002 View Post
My headlight requires the fairing structure to be mounted to... How do you remount your light?? The previous owner of mind really jacked up the fairing...
I mentioned in my post that I basically ziptied the light to the fairing stay as securely as I could using the little holes on the housing, fine for me since it's only a temporary measure before switching to something new entirely. It seems sturdy enough, but if you were planning to just mount the headlight to the fairing stay permanently then I'd probably pick up some thin metal bars and fabricate some custom brackets.

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post #13 of 15 (permalink) Old 2-10-2020, 1:37 AM
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Hey so i broke the fairing on my left side that contains the left turn signal. the turn signal is fine but the fairing would be a pain to replace, so id rather just streetfighter it. I wanna replace the headlight and the turn signals with just a round headlight that contains turn signals. Anyone know a good headlight and if so, would i need a mount for it?
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post #14 of 15 (permalink) Old 2-10-2020, 5:33 AM Thread Starter
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Originally Posted by Vecktor View Post
Hey so i broke the fairing on my left side that contains the left turn signal. the turn signal is fine but the fairing would be a pain to replace, so id rather just streetfighter it. I wanna replace the headlight and the turn signals with just a round headlight that contains turn signals. Anyone know a good headlight and if so, would i need a mount for it?
I'm most likely gonna go with the recommendation zerofret gave, a headlight from 4into1.com. Got a bunch of options for the look of the light, and they also sell mounting brackets and turn signals that can also screw into those brackets. You could definitely find cheaper stuff on ebay, but the site seems legit so I'll just spend the money.

the name's rex. happy to be here.
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post #15 of 15 (permalink) Old 2-13-2020, 5:27 AM
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I bought a pair of led lights, completely changed the drivability, i could bearly see anything with halogens, now am happy, and people see me better
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