Post by Mainely Scooters on Nov 21, 2013 23:32:05 GMT -5
I found out a way this summer to retromod 2008-2013 Sunny style scooters to fit a Halogen Headlight Bulb. This *may* work on other scooters. It is reversible if you are careful. Otherwise you have to purchase a whole new headlight assembly if you want to revert back as the socket is not typically available separately. This mod works best for scooters with the 25w Incandescant bulbs.
We always have lots of 35w/35w halogen bulbs in the shop. The specific model is important as it has to have the two electrodes on the bottom, and it can't be too large. You'll see below.
Pulling out the headlight assembly and the headlight socket you can see the bulb *just* fits inside. Looking from the side you can see how the flange nicely fits inside the retaining ring area.
From behind rotate the bulb until the contacts match up with the metal prongs. Carefully bend the prongs down until they fit snugly against the bulb contacts. You will have to remove the bulb to bend the contacts enough. It will take a few tries. Make sure the contacts DO NOT TOUCH or you will have a melted rectifier.
If you have the bulb backwards, its ok, high and low will just be reversed. Test before you close everything up.
If you look closely at the cutouts on the socket, you can see the aligning tab on the bulb sits in relation to the side cutout notch. It may or may not look like yours.
To affix the bulb use two small screws. Small, short, with very wide thread. Narrow thread screws won't work as they won't bite into the plastic. Screw them down on the side from the top so the entire head fits between the retaining ring and holds the light bulb flange in place. Sorry I don't have a closeup of the screws. You don't want the screws to interfere with the bulb assembly attachment. You can figure out the best placement by looking. Make sure the screws do not hit any wires and create a short. If you want you can get a bit creative to hold the bulb in place. Just remember that the bulb gets HOT.
I do not have any photos of the light, but its pretty obvious. Incandescent 25w vs. 35w halogen. HUGE difference. And it does not put extra stress on the electrical system and does not require any extra electronics or ballast like other aftermarket systems do.
Greg
Mainely Scooters
We always have lots of 35w/35w halogen bulbs in the shop. The specific model is important as it has to have the two electrodes on the bottom, and it can't be too large. You'll see below.
Pulling out the headlight assembly and the headlight socket you can see the bulb *just* fits inside. Looking from the side you can see how the flange nicely fits inside the retaining ring area.
From behind rotate the bulb until the contacts match up with the metal prongs. Carefully bend the prongs down until they fit snugly against the bulb contacts. You will have to remove the bulb to bend the contacts enough. It will take a few tries. Make sure the contacts DO NOT TOUCH or you will have a melted rectifier.
If you have the bulb backwards, its ok, high and low will just be reversed. Test before you close everything up.
If you look closely at the cutouts on the socket, you can see the aligning tab on the bulb sits in relation to the side cutout notch. It may or may not look like yours.
To affix the bulb use two small screws. Small, short, with very wide thread. Narrow thread screws won't work as they won't bite into the plastic. Screw them down on the side from the top so the entire head fits between the retaining ring and holds the light bulb flange in place. Sorry I don't have a closeup of the screws. You don't want the screws to interfere with the bulb assembly attachment. You can figure out the best placement by looking. Make sure the screws do not hit any wires and create a short. If you want you can get a bit creative to hold the bulb in place. Just remember that the bulb gets HOT.
I do not have any photos of the light, but its pretty obvious. Incandescent 25w vs. 35w halogen. HUGE difference. And it does not put extra stress on the electrical system and does not require any extra electronics or ballast like other aftermarket systems do.
Greg
Mainely Scooters