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Headlight Mod: In over my head!

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32K views 71 replies 28 participants last post by  briang  
#1 ·
Hello all. Im new to this.

here's what I have: 2002 warrior with standard headlight

Here's what Im interested in doing: I want to replace the h4 bulb/housing with the Harley davidson LED headlight (5 3/4) unit.
(link : Black LED Headlamp | Genuine Motor Accessories | Harley-Davidson USA )

Here's the problem: how the **** to get the light mounted to the spring loaded aiming jig!?!?

The LED Bulb housing fits inside the warrior housing, wiring and all, but obviously there's more to it... and it requires more fabrication know how than I believe i bring to the table.

Im in Boston MA. Is there anyone near me that is interested and has fabrication know how?
 

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#6 · (Edited)
My guess is it'll need a new bucket. Not only will the hardware not connect but it seems a sure thing the LED
componentwill over-fill the Warrior's stock bucket leaving no room for the wiring / connectors that live in there.

If I was going to change buckets, I've always liked the Mariah bucket:
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#8 ·
New Bucket?

ARIZONA - the stock warrior plugs right into the harley led module! If i hold the led module in placew, front flush with where the stock halogen reflector normally sits in the trim ring, theres room behind for the wiring (as much as the stock reflector at least).

I wondered if it would be easier to simply put a new Harley Bucket on the warrior, and put the LED light in its native bucket.

My question: Is it a big deal to swap out the bucket? I have the tach cowel and i like look of the stock set up.

Doesn't the warrior bucket have a ton of back cutouts and top mounting treads for the tach?

Im sooooo new at all of this...but i know i want the led light on the bike.
 
#9 ·
If you swap the bucket its a good time for a front-end clean-up because the HD buckets mount differently so the bits surrounding the stock bucket will have gaps in between and look odd. There's a number of members who have done that in different ways, but I have not so a forum search might be a better way to get info.

The LED looks as deep as the tip of the H4 in back of the stock reflector, but the LED is square. The wiring lays around the bucket walls as you know. I'm glad it'll fit, it must just be the pics that made me thing that lol. But I don't have a clue where to get parts that might make it fit, and making them might be the only way but how, I dunno!
 
#11 ·
thanks for the thoughts AZ. Im thinking a bucket swap might be the only option. Im not eager to tackle all those wires behind the headlight. Ill start a new thread about Swaping buckets. Spending $400 on a bucket, after i spent $400 on the (so far unusable HD LED light... I need to know if theres a cheap way out that keeps the front/tach/cowl/wires looking stock!

if you come across info, please PM me or post here...much appreciated.

as for the front of my bike, i didnt think it was to untidy, but we'll see what i can find on here about a front clean up. below is a pic of the front as it is.
 

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#14 ·
Hey Jason, I already talked to JW Speaker: They no longer sell that exact style to the public due to the production deal with Harley. They have other models that can be had through their distribution points, but that specific model which has been vibration dressed, is only avail through Harley.
 
#20 ·
wyomingwarrior, do you have any more pics or details about how you ran your wires? I see you drilled that 2" hole in the gusset plate, but where do they come out?

I relocated my keyswitch under my seat, replaced my stock headlight with a Victory triangular headlight and have some other wiring work I've done. What I'd like to do is relocate the wiring (all that i can anyways) to under the tank so you can't see it. However, I'm open to ideas and am intrigued with your setup.
 
#21 ·
nevermind....sorry....just read that complete thread that was linked earlier. Great ideas! I'm not sure what i'll be doing. I think I'm still going to wire under the tank so as not to compromise the frame integrity too much. However, I still may run the headlight wires through there. I'm not 100% on anything just yet. I figure I'll do it this winter so that I can ride now, research and plan now, then execute this winter. I plan on removing my triple trees and powdercoating/shaving them this winter as well, so I might as well knock everything out all at once.
 
#27 ·
Is anyone still interested in this??

Ive had a custom made billet 6061-T6 aluminum adapter made using the internal parts of, and designed to attach to, a stock warrior bucket. It mounts the same (top clip/hook and 2 side screws) and is adjusted with the same spring loaded diagonal set screws on the sides, exactly like a stock light.

NOTE: the chrome bucket ring was for design & fitting only (extra i bought just for this project). I plan on keeping the black/brushed aluminum motif on my bike now...

Its not bike ready yet, just some cosmetic things to finish...but the worst of it is behind me...except for the bill!!
 

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#37 ·
Mount that puppy and lets see a few pics day and night!

Luv2LafMcc said:
Is anyone still interested in this??

Ive had a custom made billet 6061-T6 aluminum adapter made using the internal parts of, and designed to attach to, a stock warrior bucket. It mounts the same (top clip/hook and 2 side screws) and is adjusted with the same spring loaded diagonal set screws on the sides, exactly like a stock light.

NOTE: the chrome bucket ring was for design & fitting only (extra i bought just for this project). I plan on keeping the black/brushed aluminum motif on my bike now...

Its not bike ready yet, just some cosmetic things to finish...but the worst of it is behind me...except for the bill!!
Click to expand...
 
#29 · (Edited)
hey Yune, No electronics or weatherproofing NEED to be worked out!

The stock warrior halogen bulb is an H4, and the HD LED unit is also H4; Plug and go!
The stock Warrior bucket and bulb is not watertight...its exposed. The HD LED light is a sealed, waterproof aluminum unit. I had some Tech talks with JW speaker Co about it.

Mount it exactly like a stock headlight...plug it in...pop'yo coll'ah as you ride by everyone else with halogen or HID bulbs...:D


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#30 ·
Looks good man, was curious where you ended up on this. Now mount it up so we can see what it looks like turned on and at night!
 
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#31 ·
Im try'n Jbat!!! My hope is to at least match, or improve upon Yune's efforts that he had posted with his dual projector beam shot below... He seems to be the only brave soul here that is haunted with doing something different to the warrior light without changing it too much...I'll get one of my own up as soon as i can!


(yune's beam pattern below:)
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#33 ·
The Death Star isnt real Leader...so STOP BEING RIDICULOUS!!!!

if it lights up like a moderate pulsar or a really good lighthouse...I'll break even!!!

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but now that you mention it... a Death Star type headlight would be the $hit!

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#39 ·
Its alive!!!!!

Ok guys, its DONE! FINALLY! Took me 60 days...and don't ask how much $$ cause it was FOOLISHLY & IRRESPONSIBLY expensive...but I never let fear or common sense stop me before, so why start now...

I haven't had a chance to see it at night yet, but considering the beam was visible on an outside wall, at 4pm on a sunny day, I have high expectations for it being "bright" tonight when I take her out.

I brushed the milled aluminum "adapter" which mounts the LED light to the stock warrior headlight front ring, which mounts to the stock bucket. The added distance is to allow the back of the LED unit space, as i still have all my wiring connections inside the bucket.

All internal stock aiming mechanisms are 100% functional. the LED unit is secured at 12/3/6 & 9 o'clock with bolts (blue locktight of course). Internally, I also have a safety wire through looped. Of course the hi/lo functions with stock thumb switch setup. Plug-n-play from behind the front ring back.

The top projector is the low beam, bottom projector is the high beam, both side "D" lenses are side casting fog lights that remain lit for both hi/lo mode.

Pictures are worth 1000 words, so I'll shut up and let you click on the bike-porn below:

**Here's a link to my lower fork lights http://www.rswarrior.com/forums/13-...chnical-discussion/182243-led-fork-driving-lights-install-pics.html#post2331602

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