daxman wrote: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;"