Headlight mounting ideas?

Colorado Mike · Post by **Colorado Mike** » 09:19 am May 30 2006

Anyone come up with a mounting system for the stock light that doesn't involve tie wraps?

If not, anybody have recommendations on an aftermarket unit that works well and is easy to live with?

Post by **Indawoods** » 09:23 am May 30 2006

I used the original rubbers on the top... stretched to the max... but it holds, and ty-raps on the bottom, not super tight but just enough to hold it steady.

Works well so far....

Colorado Mike · Post by **Colorado Mike** » 09:50 am May 30 2006

rubbers on the top? Weird. Mine was bolted-on top and bottom.

Green Hornet · Post by **Green Hornet** » 01:05 pm May 30 2006

WER sells a mounting kit that raises the headlight for the WER Damper. It uses straps and costs like $15- I used Tie Wraps.

part # Hdlt Mnt Kit KDX 04-14400 $14.95

canyncarvr · Post by **canyncarvr** » 02:15 pm May 30 2006

Something basic is missing...

You're wanting to mount the OEM shell?

Any mounting kit for an aftermarket (like UFO) shell will work. They are rubber straps with a molded-in hook/latch (made of rubber). Just stretch'm and latch'm.

re: Stretched to the max..

That's cuz you have the type intended for conventional forks. Get a 'kit' for a USD bike...like the KX. You can attach the 'nipple' to the OEM shell in a variety of ways. Use the existing bracket mounting holes or drill some new ones to suit.

Any mount kit intended for use on the KDX will have the smaller straps. Yep. They are indeed a very tight fit!

Green Hornet · Post by **Green Hornet** » 02:33 pm May 30 2006

True, all bow to the Carvr

I forgots all abouts that

canyncarvr · Post by **canyncarvr** » 03:06 pm May 30 2006

Just don't ever let it happen again!

Post by **Indawoods** » 06:39 pm May 30 2006

It is bolted...

I had some misc rubber straps and weird hardware and come up with something. I deleted all the HARDware and went all soft ecept for a few washers that keep the strap buttons from coming out of the holes.

I guess you'd have to see it....

IdahoCharley · Post by **IdahoCharley** » 10:46 pm May 30 2006

I reused the upper metal mounting tabs and fork mounts on the stock light. On the bottom mount I removed the metal inner reinforcing frame and then used headlight mounting straps from a KTM light to mount the lower portion of the light to the forks. The lower mounting holes in the light shell with the metal bracket removed were perfect size for the mounting strap tits to attach.

FWIW - When I first looked at the KX triple tree I planned on using the upper metal and lower metal mounts. The upper as a plug and play and the lower ones I was going to mount to the stud bosses which are cast into the lower triple tree. I figured I would drill and tap the blank stud bosses and then use either a metal strap to the original mounting system or fabricate a different reinforcement/mounting bracket for the lower part of the light shell.

Colorado Mike · Post by **Colorado Mike** » 09:32 am May 31 2006

Thanks Charley,

I'll take another look, but my upper clamp is a Scotts, and these are '03 forks. The stock clamp had the bolts coming in from the rear, the Scotts go in from the side. Maybe I can build some new upper brackets.

Green Hornet · Post by **Green Hornet** » 10:34 am May 31 2006

Colorado Mike wrote:Thanks Charley,

I'll take another look, but my upper clamp is a Scotts, and these are '03 forks. The stock clamp had the bolts coming in from the rear, the Scotts go in from the side. Maybe I can build some new upper brackets.

Mike-Theres always Duct Tape

IdahoCharley · Post by **IdahoCharley** » 10:57 pm May 31 2006

Mike - The rubber strap attachment both upper and lower would be an excellent option I think. I did not know that strap kits could be bought until CC mentioned it - it sure would make it easy based upon my experience. Pull the metal brackets insert the rubber straps and latches - install around fork leg = Done.

canyncarvr · Post by **canyncarvr** » 02:04 pm Jun 01 2006

re: 'I did not know that strap kits could be bought..'

I bought mine..but that was when looking around Steahly's shop, spied 'em, said, 'How 'bout those?'

Buying them out of catalog? With a part number? Don't know about that.
.
.
.

OK. Legwork done.

I called Mr. Steahly. He DOES have the strap kits available as a separate item. He asked 'what shell', but that doesn't matter in this case. You can find him (contact info) on the web..or:

Toll Free- 800-800-2363
8:00am - 6:00pm PT Mon - Thurs
8:00am - 4:00pm PT Fridays
Closed Sat. and Sun.

From...

http://www.steahlyoffroad.com/

As long as they are for USD forks..and have some 'tit-type' (I didn't want to say that..but it's already been said) attachment method, you're home free.

I smushed my OEM shell a number of times..the hard (metal) attachment method was NOT my friend. I've smushed, knocked off and otherwise offended my aftermarket shell with the 'soft' straps...much moh better in terms of NOT damaging the shell itself.

If you like, I'll pick you up a set and mail it your way.

BTW..maintenance is much easier with the strap-mount method. Changing bulbs, fork access...the whole shell is off in seconds. Well..I put solderless connects where required (lights, grip heat...heh heh..). a MUCH simpler task than taking out the hardware.

If you call Mr. Steahly, say something about days getting shorter in a couple weeks....JUST to keep him from getting too happy...........

Colorado Mike · Post by **Colorado Mike** » 10:15 pm Jun 01 2006

Okay CC I'm sold. I'll see if I can order a set tomorrow. My tie wraps are holding for now, but I need something mo bettah.

Post by **Indawoods** » 10:17 pm Jun 01 2006

What... you too good for twine and ductape?

Let us know what they cost... mine are steeeetched bad.

IdahoCharley · Post by **IdahoCharley** » 10:32 pm Jun 01 2006

re "and have some 'tit-type' (I didn't want to say that..but it's already been said)"

Thought also about that - this being a family board and all that - but could not come up with a better word at the time. Now if I were a pipe fritter those dang guys are always dealing with nipples, cups, joints, male and female parts and they get them cold, make them sweat, wet them down with resin, wipe them while they are hot, etc., etc.

canyncarvr · Post by **canyncarvr** » 03:19 pm Jun 05 2006

CM? Done? On the way?

...thought I'd asked that last week...but no post to that effect now.

Colorado Mike · Post by **Colorado Mike** » 09:15 am Jun 06 2006

nope. been busy doing 3 guy's jobs at work. Tried a little to find them locally since I hate paying $12 shipping for a $8 part. I'll try calling Steahly today.

canyncarvr · Post by **canyncarvr** » 12:18 pm Jun 06 2006

I could ship it to you for less...and wouldn't charge any handling fee, neither. What a deal!!!

If you want 'it'..let me know what 'it' is and I'll pick it up, send it your way.

Add anything else you want that will ship cheap (light)....let me know.

Colorado Mike · Post by **Colorado Mike** » 05:10 pm Jun 06 2006

Thanks CC, I just called them, they had to order the stuff but said it would ship to me in a couple days. $7 something for the part and $7 something for the UPS shipping . I think they said USPS would only be $4, but Those guys take too long to get stuff to my house. Thanks for the offer, but this way it's less hassle. Thanks too for the tip, those guys seem good to deal with.

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Headlight mounting ideas?

Headlight mounting ideas?