Aux light project for Honda 250 Rally

Foreword

This is going to be a long winded post so bear with me. As for aux lights, the easiest solution would be to go with something like the Denali mounts and mount separate lights to the fork tubes.

I wanted something different for 3 reasons.

  1. I wanted the light(s) to be as crash proof as possible, meaning that I wanted to place them on the center of the bike.
  2. I wanted lights that would NOT turn with the steering
  3. I wanted to tinker…

Whether all this makes sense is another matter entirely.

The mounts

After some head scratching, I found that there is a cross tube below/behind the light that would allow me to insert a threaded rod through providing a relatively solid mounting point.

The idea was to construct 2 steel bars that would mount on the rod and rest on top of the fairing mounting tab. The mounting hole is drilled so, that the mounts would set on a slight downward angle to match the top line of the fender and not block the actual driving lights.

IMG_20180217_162622
Ghetto electrical tape bushing on the threaded rod
IMG_20180217_163036
Rubber grommet placed on the fairing mounting point

The light seems to fit very securely in place, but for “hard enduro” purposes it may require a few zip ties to keep it from moving upwards. Remains to be seen if it becomes an issue.

As it sits now, the light should be as crash proof as it can be. Crashing on either side should not affect the light.

The light

Once I had the mounting figured out, I knew what kind of light I needed. For this purpose, an 8 inch wide single stack LED light was ideal. Mine is not-so-high-quality one from Wish, as I wasn’t sure if this setup would work. In retrospect I would maybe go with something a little better, like this

61SU+WvhikL._SX522_

» Rough Country – 70718BL – 8-inch Black Series CREE LED Single Row Light Bar for Anywhere You Can Mount It

from Amazon.com.

Lots of options out there. The key is to have mounting holes in the ends.

The switch

To give the project some extra challenge, I wanted the switch on the dash, not on the bars. Placing the switch on the bars is a no brainer, but I wanted to figure out if there was a way to mount it cleanly on the dash.

I discarded the switch that I had an ordered a better looking one. This:

51ywX4ZqLvL._SY463_

» Feiteplus 7/8″ Motorcycle Handlebar Mount ON-OFF Switch DC 12V For Motorbike Fog Lamp Head Light Electrical System

I found another tube under the dash, that again allowed me to insert a threaded rod for mounting.

I wrapped some electrical tape on the rod for a rattle free experience and snug fit.

IMG_20180301_203614
The mounting rod. Notice the bushings made out of electrical tape.
IMG_20180301_210655
Added rubber grommets on both ends for a friction

On the rod I placed an aluminum spacer (unfortunately not black) that would allow the clamp of the switch to be attached securely.

IMG_20180301_204558
Aluminum spacer on the end

The other end of the rod is capped by a nut and there is no room for anything else as the ABS switch gets in the way. (removed in the pic for installation)

IMG_20180301_204447
The other end

The location of the switch allows the wires to run very cleanly and not bind in any situation, as nothing moves with the steering.

IMG_20180301_212512

IMG_20180301_211106
The view is rather clean.

I’m pleased with myself, that I could figure out a working solution, but I will tinker with it some more. My plan is to have the standard high beam switch control both the high beams and LED bar and have the newly installed dash switch in between. This would allow me to have the led bar either to switch on when high beams are turned on or stay off at all times.

 

FUJI1414
The light could be a tiny bit wider for optimal fit

FUJI1405

FUJI1400
The ideal width of the light bar would be 210mm. I had to use some spacers on mine.
FUJI1412
The front looks even goofier now

lightmount-01

FUJI1416
Enough room to adjust the beam
Honda CRF 250 Rally LED bar aux light
Honda CRF 250 Rally LED bar aux light
FUJI1392
mounting point (nyloc nuts not yet installed)
FUJI1418
The mounting bars rest on the fairing mounting point

FUJI1421

IMG_20180325_132931

Advertisements

2 Comments Add yours

  1. Andrew King says:

    Very nice. Well done for taking a new approach 👍🏻

    Liked by 1 person

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google+ photo

You are commenting using your Google+ account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s