Sportster headlight on an SR500

I got the seat pad shaped and dropped off at the upholstery shop, so doing a few other small things while I wait. With the new slimmed down look of the bike, the stock headlight was looking too bulky, so decided to change it.


Two possibilities from the parts stash, an XJ750 auxiliary light, and a Sportster headlight. The XJ750 auxiliary light would look neat with a hole cut in a number plate, but the Sportster light gives a neat 70's enduro look. The XJ750 light is only 35 watts, but takes a standard H3 bulb, so would probably give decent, but not great, lighting, but no room to hide the electrical connections. The Sportster light takes an H4 bulb, and has enough room for the connections. It really came down to me preferring the enduro look over a number plate.


The stock headlight and electrical connections. It will be tight, be should be doable.


The stock headlight mount, which will be replaced with a simple bracket.


Starting with a piece of 3/16" x 2" steel.


The first bend...


...and bent roughly to the final angle. Then 3 holes and some trimming.


It will bolt to the stock bottom headlight mount holes. I cut the heads off of a couple grade 8 bolts to make studs. It makes it stronger, and a bit easier.


Test fitting the new bracket...


...and the headlight.


Yes, the stock gauges are big and goofy looking, but I like them.


I'll test ride it before painting the bracket, to make sure the angle is good, and in case it needs gusseted to prevent any headlight bouncing, but it should be fine.


Since the headlight is mounted upside down from the top mount on a Sporster, I needed to flip the lens.


Just a new notch cut in the mount rubber for the lens tab, and it's flipped. I'll also seal up the original drain hole in the shell, since it is on top now, and drill a new one on the bottom.