Suzuki 2 Strokes

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

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

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

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

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.

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-p ... t-assembly

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

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.