Replacement Headlight, 78 E

[Sid]

I have a 1978 XS11 Model E (actually produced in '77 with a low serial #). The headlight low beam went out this weekend (I think it may be the original bulb?). My Haynes manual shows that in '78 the headlight was all one unit, but in '79 it was changed to have a bulb screw into the back of it.

My local Yamaha dealer tells me the headlight is no longer available. What is the best solution? Should i upgrade to a '79 rectangular assembly with the replaceable bulb? Is there a secret source of bulbs (this is a 'Stanley').

Thanks in advance for any suggestions!

Sid

[skids]

Re: Replacement Headlight, 78 E

Sid, the upgrade to h4 bulbs is a good thing. Take a good look at the stock sealed beam "bulb" and note the adjustment flanges that are integrated onto it. Go with ebay or a bone yard for the conversion. The JC whipmes do not work because they are sans flanges!!

[TopCatGr58]

Hey Sid,

Here's another alternative I found. Mike'sXS has the 5" x 7" rectangular headlights and buckets for sale in black, only about $34.00. You don't even need to use the bucket, just take the headlight out of it and put it in your headlight assembly!

Rectangular 5 x 7" Headlight Assembly with halogen lamp - Black - Ideal for
use when building street trackers. 9/16" Mount holes.

See picture:


Also, the JCW bulb are the wrong size, they are either 4x6 or 6x8, and yours is a 5x7!

Hope this helps!?
T.C.

[Sid]

Skids,

Thanks for the reply! By "ebay or boneyard", you mean I should get another headlight that is not completely sealed, correct? I have noted the 2 flanges and mounting screw. I assume that a '79 headlight (lens cover and back) have the same flanges and will correctly fit into the black casing? Then, an h4 lamp will be able to be inserted into this unit?

Any cautions on type of bulb (the old bulb always sucked at night - too dim). Can I go with a brighter white without causing problems with the electronics (just keep it at the same 65/50 wattage?). Apparently the original was not a "quartz" bulb, either. Haynes just calls it a bulb while the UK version and later US versions had "quartz" bulbs.

Sid

[TopCatGr58]

Hey Sid,

I had just looked up in the Yamaha fiche, and the bucket and rings are the same for the 78 as the 81, it was the bulb/reflector that was changed from sealed beam to housing and H-4 Bulb design, so any later year XS11 Standard will fit!

Folks have even gone to the brighter 100/80 watt bulbs available from motorcycle supply sources, ie. JCW. As long as you haven't added a bunch of aux. lights, should have no problem running the higher wattage bulb.

With the MikesXS unit, you would be guaranteed a pristine reflector inside the housing. Some of the OEM's may be rather dingy, rusted, pitted, etc.!
T.C.

[skids]

Originally posted by TopCatGr58
Hey Sid,

I had just looked up in the Yamaha fiche, and the bucket and rings are the same for the 78 as the 81, it was the bulb/reflector that was changed from sealed beam to housing and H-4 Bulb design, so any later year XS11 Standard will fit!

Folks have even gone to the brighter 100/80 watt bulbs available from motorcycle supply sources, ie. JCW. As long as you haven't added a bunch of aux. lights, should have no problem running the higher wattage bulb.

With the MikesXS unit, you would be guaranteed a pristine reflector inside the housing. Some of the OEM's may be rather dingy, rusted, pitted, etc.!
T.C.

Just make sure that you ask the seller if it is a "sealed beam" or a lens that accepts the bulbs. I have gone the JCW route with the high wattage bulbs and in my opinion they are junk. I am using Sylvania Silverstar 60w/50w (or is that 60W/55W) bulbs and they are very bright without the additional current draw. I have not tried Mike's lens/reflector.

[Sid]

Thanks Skids & TC!!!

I have found a guy up the road who sells parts, and is a former XS owner. He is only open on Saturdays, but told me to swing by this weekend with the sealed beam and he should be able to get me set up with the proper replacement (he thinks he has a few to pick from, so I'll be sure to get a clean one!). He has a large barn filled with parts, and specializes in Japanese models.

While I'm at it, I will most likely get a new bulb and will try your suggestions. The machine is pretty much original without any added lights or gadgets, so I guess a few more watts won't hurt (as long as the wiring can handle it).

I'll post back with the final outcome later this weekend.

Sid

[Sid]

Here's the result:

I went to a local parts barn (Bob has 3 floors of sorted parts in his barn, and a wealth of know-how). He rode an XS rat-bike until sidelined by a medical condition a few years ago. His contact info can be found at mcsalvage dot com, and he specializes in Japanese parts.

I was looking for the replaceable light from a '79 or '80 (F or G model) to fit into my headlight casing but except an H4 bulb. He only had a '78 sealed beam but I was afraid that was jumping from the frying pan into the fire and I would be at it again in 6 months. I also tried to fit another bulb (forget the model) but the flanges just were not in the same spot and would not line up correctly.

After an hour plus of contemplation and searching, I settled on a round headlight assembly from an '80 XS. It fits nicely into the fork mounts, and the halogen bulb is so much brighter. I also prefer the look of the round assembly (I know, not original... but function is key right now).

So I am back on the road, with a slightly different look and improved lighting. Thanks to all who offered advice (glad i found this resource).

Sid