Headlight options..

[daxman]

I bought a generic 7" Halogen headlight with plastic shell for the GT250 as the glass lens is broken in mine and the chrome shell is quite rusted. I now notice that the original light is only 6.5" and the mounting points are inset a bit making it all quite a bit narrower. I also fear there is less room in the 7-incher for all the junctions. So.. can you get a replacement beam unit that will fit the OE shell anywhere or do I buy another complete unit size 6.5" ? Suggestions welcome. Ta.

[Frank T]

I would consider something like eBay item 191775135915. The seller is located in the UK.

[jabcb]

You can use a halogen headlight from a Suzuki GS L model. (Other Suzuki GS models use headlights that are either too big or too small.)
The alternator output is meager, so you will need to use a reduced output H4 bulb.
A different headlight rim is needed to fit the headlight to your stock headlight bucket.

More info: viewtopic.php?f=2&t=10745&p=147762&hili ... ht#p147762

[dollydog]

i bought one of these. all metal, fits nice on the gt550 forks and looks great. all the wiring fits well inside. even got a sidelight. £34 including post, what more do you want? https://www.ebay.co.uk/itm/Bike-It-Moto ... rk:38:pf:0" onclick="window.open(this.href);return false;
cheers, dd.

[daxman]

Good suggestions - thanks all.

[dorT500]

If originality is everything to you, then you might consider these two items and then be done with worrying about the headlight. If your old headlight was a sealed beam unit than all the better....just pop in another bulb in the type below should one burn out in the below unit. Those old Stanley brand bulbs (available on ebay) seem to last forever. T500 OEM bulbs are 35/25 watt. Of course you would want to see if the stock/standard filament bulb with the proper wattage is available.

https://www.ebay.com/itm/NOS-OEM-Suzuki ... 1#viTabs_0" onclick="window.open(this.href);return false;"

https://www.discountbikespares.co.uk/pr ... 250-gt185/" onclick="window.open(this.href);return false;"

Here is one I bought on ebay from Indonesia.. (35100-36131-999)



107.88 GBP discountbikespares headlight unit

+ 55.71 GBP ebay headlight bucket. Currency conversion based on this date.
_______
163.59 GBP plus shipping

Nice little chunk of change, yes, but.....


if I were you, I would add up the costs of the the various options listed by others.....add to that the cost of a modern rectifier/regulator combo (around $50.00 ?)you would want to add if you upgrade bulb wattage and/or you upgrade to an AGM battery which should be use when a modern retifier/regulator combo is installed.

Just sayin...

[sportston]

Or cheap halogen headlight with LED bulb so it doesn't pull too much current?

[dorT500]

I bought a generic 7" Halogen headlight with plastic shell for the GT250 as the glass lens is broken in mine and the chrome shell is quite rusted. I now notice that the original light is only 6.5" and the mounting points are inset a bit making it all quite a bit narrower. I also fear there is less room in the 7-incher for all the junctions. So.. can you get a replacement beam unit that will fit the OE shell anywhere or do I buy another complete unit size 6.5" ? Suggestions welcome. Ta.

Kinda of a jumbled bunch of text I posted here....I should have edited it up some but hope one of the options will help. Good Luck

Please read on at the bottom for other another option that should work for you.


Not 30/30 but here is a A7025 incandescent bulb 35/25 watt....



1 1/4" x 5/8" rubber grommet to fit in an appropriate size hole you can cut in the reflector (this is for a 35/25 watt bulb, smaller wattage the glass bulb may be smaller.




Another way...

snip for some tabs you can use to hold A7025 bulb flange in place on both sides and spot solder a couple a places for extra hold.



Another way.... I used a Sylvania H5006 35/35 headlight to do it on my T500 (stock voltage regulator)....it burned out in a few months and never figured out exactly why but anyway, got the idea from here... http://www.oregonmotorcycleparts.com/FAQ.html" onclick="window.open(this.href);return false;"

Carefully break the glass lens while you have it in a heavy paper bag, remove any remaining glass and adhere this headlight https://www.ebay.com/itm/NEW-12V-Wagner ... 2558367117" onclick="window.open(this.href);return false;" or one like it from your side of the big pond headlight to your reflector with red high temp RTV silicone gasket maker. I also put a thick bead around the front of it (sloppy job but it was just temporary) In a pinch (state inspection was due) I did this to an old spare dead sealed beam headlight I had. I also ran an 'eyebrow' over the hole to minimize any moisture running down the reflector.

https://www.ebay.com/itm/NOS-Stanley-He ... 1720114486" onclick="window.open(this.href);return false;"

https://www.ebay.com/itm/NOS-Honda-Kawa ... 888079786I" onclick="window.open(this.href);return false;" needed a quick solution for a yearly state inspection but I'm unable to find a picture of it right now. I also filled the small space around the beam unit and the rim with high temp silicone mentioned below.....not real pretty but will worked for what I needed at the time.

Back to the bulb options...
This is not an A7025 bulb (different flange) but the one below is. https://www.ebay.com/itm/NOS-Stanley-He ... 1720114486" onclick="window.open(this.href);return false;"

https://www.ebay.com/itm/NOS-Honda-Kawa ... 0888079786" onclick="window.open(this.href);return false;"

[jabcb]

.... I used a Sylvania H5006 35/35 headlight to do it on my T500 (stock voltage regulator)....it burned out in a few months and never figured out exactly why
...

The stock voltage regulator allows the voltage to get as high as 16V. That’s too high for modern batteries & lights. Upgrade to a modern rectifier/regulator to keep voltage below 14.5V.

[dorT500]

[quote="jabcb"][quote="dorT500"].... I used a Sylvania H5006 35/35 headlight to do it on my T500 (stock voltage regulator)....it burned out in a few months and never figured out exactly why
...
[/quote]
The stock voltage regulator allows the voltage to get as high as 16V. That’s too high for modern batteries & lights. Upgrade to a modern rectifier/regulator to keep voltage below 14.5V.[/quote] Thanks for that clarification. I've always envyed your expertise on the ignition and electrical issues over the years. For now, I'm happy with the 'plug & play' headlight above I bought. Got tired of modifying dead sealed beam spares over the years.

Thanks again.

Sorry about this disjointed text.....used my phone ....hassle sometimes.