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Aftermarket headlight

Discussion in 'The Garage' started by cutlass400, Mar 7, 2018.

  1. cutlass400

    cutlass400 XS400 Member

    headlight.jpg Thought some people might get a laugh/idea out of this. This is how I used the stock headlight with a 9003 aftermarket bulb. I did this probably 10 years ago at a much younger age but surprisingly held up. I used quick steel to hold bolts to the back of the headlight I can't remember what I used for the retainer maybe a metal hanger and I held the ends together with a yellow butt connector. I used a silverstar ultra and that thing is bright. I also can't remember how I got the original filament out without breaking the glass and the dumb doesn't fit exactly on the original headlight but it's good enough and everything fits in the headlight bucket with all the factory wiring. I thought about trying to use an LED bulb but I don't think it will fit inside the headlight bucket.
  2. BBS360

    BBS360 XS400 Guru Top Contributor

    Looks good. How's the beam pattern?

    I had been debating doing the same to mine. Broke the old bulb out and was puzzling over how to mount and retain the H4 bulb.

    Gave up and ordered a 5-3/4" LED and bucket from China.
    Fingers crossed it'll install smoothly when it gets here.
  3. cutlass400

    cutlass400 XS400 Member

    The pattern is wide and very bright. Since i have aftermarket turn signals holding the bucket in I can move the bucket up or down while I'm riding if i have to. I'd like to see how your LED's lights fit Ive heard the xs 400 headlight is very specific but anything can be made to fit.
  4. BBS360

    BBS360 XS400 Guru Top Contributor

    Yeah, stock headlights are apparently around 6-3/8”. Candlepower used to make a 6-3/8 headlight that took H4 bulbs but their factory was in the Fukushima exclusion zone so there are no more being made.
    I’ve read that some members have fit 7” LEDs in the stock bucket with some modification.
    Actually looked like the 5-3/4 might be easier to retrofit in the stock bucket but my headlight ring is pretty banged up so I didn’t want to reuse it.

    Ordered a matched set, 5-3/4” LED headlight, 5-3/4” bucket, and mounting brackets. Not sure how I’ll end up mounting the stock headlights.
    Into the bucket if the bolts will fit, otherwise onto the brackets.
  5. franticvike

    franticvike XS400 Member

    I'm thinking of doing something similar. My lens is cracked, beam is weak and I can't get it to align properly for any kind of decent illumination. What did you settle on to mount the aftermarket bucket?
  6. WelderDave

    WelderDave XS400 Addict

    I went with a daymaker knockoff with mounting brackets. All LED, looks pretty good and fit right up. Came with its own bucket.
  7. Durney

    Durney XS400 New Member

    I went to Walmart and bought a 7in halogen for 8 bucks. Modified the chrome ring to hold the headlight. Bright and cheap.
  8. franticvike

    franticvike XS400 Member

  9. franticvike

    franticvike XS400 Member

    The light looks decent and wired right up with standard H4 (on my 82 DOHC). My bucket is a bit warped though and the bezel is also not in great shape, so I spent most the time fighting that. Will try to get a shot of the light on a wall to show the pattern.

    IMG_5358.JPG IMG_5357.JPG IMG_5304.JPG
    Denis Normandeau likes this.
  10. Robsteeler66

    Robsteeler66 XS400 Addict

    Welder Dave, do you have a link to the model you purchased?

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