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PostPosted: Mon Dec 21, 2015 7:21 pm 
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On the street

Joined: Wed Dec 08, 2010 6:53 pm
Posts: 45
Location: north Ontario Canada
Country: Canada
Bikes owned: 1972 T250 1976 GT500A(sold)
Hello all,
I've done some searching but admit that after several pages of posts containing the word "headlight" I have resorted to asking this question. Sorry if this has been discussed before---
I'm just getting started on rescuing a '72 T250. It has the flat bottom headlight, the "no bucket" style, sealed beam. Works on high, not on low beam. Replacements are quite highly priced, rightly so I suppose as working ones are rare.

My question is; has anyone tried to convert/replace the bulb on one of these? The rear of the sealed beam structure is some sort of metal, (magnet sticks good) and I wonder if the old bulb end could be cut off allowing the removal of the bulb. The large globe would have to be broken to fit through the hole that would be left by cutting off the socket part of the bulb.
Then could a modern slim bulb be somehow soldered in place? Perhaps the hole would need to be enlarged slightly to accept the modern globe but some sort of plate could hold the new bulb in.

Any ideas would be appreciated.

Relic

_________________
1976 DT400C -daily rider
1972 Suzuki T250 Hustler - daily rider
1974 Moto Guzzi Eldorado sidecar outfit -daily driver
1971 Hodaka Ace 100 B+ daily rider


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PostPosted: Tue Dec 22, 2015 5:15 am 
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To the on ramp

Joined: Wed Jul 18, 2012 10:46 am
Posts: 237
Location: Eastbourne
Country: United Kingdom
Bikes owned: T500J
I saw a post somewhere where someone had updated an old headlight to take an H4 fitting. The mounting for the old bulb had been cut out, the mounting for the new bulb had also been cut out, but oversize so there was an overlap. The new fitting was held in place with 2 pack epoxy.

I can't find the post now, but it was definitely on a vintage Suzuki - a GT750 I think


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PostPosted: Tue Dec 22, 2015 5:40 am 
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AMA Superbike
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Joined: Tue Oct 14, 2008 6:47 pm
Posts: 1729
Location: Blythewood, SC, USA
I did something like that once with my GT500 headlight. Results were not that great. I think I cut the back out of the bulb with a dremel cut-off wheel. Then I removed the bulb mount from an H4 conversion bulb, and epoxied it to the old sealed beam case. It worked, but the beam wasn't very straight.....


Lane

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If you stroke it more than twice; you're playing with it.

Too many bikes, too much time, ENOUGH SPACE, FINALLY! Never enough money.........


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PostPosted: Tue Dec 22, 2015 8:45 pm 
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On the street

Joined: Wed Dec 08, 2010 6:53 pm
Posts: 45
Location: north Ontario Canada
Country: Canada
Bikes owned: 1972 T250 1976 GT500A(sold)
Thanks for the replies.
I'm going to try something as I don't have a lot to lose. I can't pass a safety check without both high and low beam working. So either I fab up something or fit some other headlight bucket in place.
I'll post again if I come up with a usable light using the original glass.

Relic

_________________
1976 DT400C -daily rider
1972 Suzuki T250 Hustler - daily rider
1974 Moto Guzzi Eldorado sidecar outfit -daily driver
1971 Hodaka Ace 100 B+ daily rider


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PostPosted: Wed Dec 23, 2015 6:18 am 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3477
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
Another option is to use a 35/35W 5.75” car sealed beam car headlight.
It fits loosely in your headlight bucket.
Just use some tape around the edge of the headlight to increase the diameter and make it fit securely.

My 72 T250 had one of these headlights when I got it.

Then keep an eye on eBay. From time to time one of the Suzuki flat bottom headlights is listed at a reasonable price.


edit: Had typo. Said Y250 & now correctly says T250.

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE


Last edited by jabcb on Wed Dec 23, 2015 9:14 am, edited 1 time in total.

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PostPosted: Wed Dec 23, 2015 7:20 am 
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Novice racer
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Joined: Wed Jan 18, 2012 8:01 pm
Posts: 946
Location: North of Albany, NY
Country: USA
Bikes owned: T500R (now), T500M (40 yrs ago)
If you are not concerned about authenticity, you can go the route I went on my '71 T500. I replaced the whole bucket with a Emgo 24-2917 7" headlight assy. It is a close match to the style of the Suzuki headlamp. I had forgotten how poor the light was on my first T500, and the difference is night and day (pun intended).

It comes with a pretty high power H4 bulb, I downgraded it to a 45W/45W (have a solid state rectifier/regulator on the bike].

If the goal is to pass inspection, and see where you are going at night, it is a good solution at about $50 USD.

http://www.bikebandit.com/aftermarket-parts/motorcycle-electrical-parts/headlights-universal/emgo-headlight-assembly


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PostPosted: Wed Dec 23, 2015 8:34 am 
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To the on ramp

Joined: Wed Jul 18, 2012 10:46 am
Posts: 237
Location: Eastbourne
Country: United Kingdom
Bikes owned: T500J
The headlight on my T500J is flat bottomed, but with a replaceable bulb. The part no. for the reflector unit is 35121-15610, so if yours could swap in, at least you would have the option of swapping the bulb rather than the whole unit when a filament failed in the future


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PostPosted: Tue Oct 22, 2019 12:29 am 
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On the main road
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Joined: Wed Oct 15, 2008 1:36 am
Posts: 103
Location: Scotts Valley, CA - USA
Country: USA
Bikes owned: T500M, T250-II, GT750J
The fix for burned-out sealed beam in my '70 T250-II was to purchase from eBay a used '71 T500 headlight and bulb harness from Canada (i.e., replaceable bulb unit, not sealed beam). Once here I used Dremel cutoff tool to remove 3 tabs from T500 headlight's perimeter (2 short tabs used for mounting to bezel and 1 long tab for adjustment screw). I then painted raw metal where I removed tabs, installed used T500 harness with new bulb, cut off the three wires and connector from my old T250-II sealed beam headlight, and soldered them to used T500 bulb harness. Also installed an old 1970's Honda rubber gauge light socket into the small parking light bulb opening in the T500 headlight. Modified assembly was a nice snug fit into my stock T250-II bezel, it appears totally stock, now has a replaceable bulb, and works like a champ - or as well as any 35/25W bulb is capable of working.

_________________
'75 - T500M
'72 - GT750J
'70 - T250-II


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