GZ250 LED headlight adapter

thingiverse

Headlight adapter ring for a 5.75" LED headlight for a Suzuki GZ250 - may fit other types of motorcycle (Suzuki or otherwise) if they use the same style headlight mounting. Designed this because the stock headlight felt inadequate for riding at night, and as the adjuster was integrated to the stock unit the replacement wasn't plug-and-play. Designed this a few months ago, have been using it successfully, and figured others might find it useful - the following instructions are what I remember of assembling and installing it. Print 2x "Front ring screw lug," 1 of everything else. Use epoxy, super glue, or Gorilla Glue to attach the screw lugs to the lower pockets (the two close together) in the adapter ring part, and the "hook" part in the upper pocket. (These are separate as printing these parts in the Z-direction on the adapter ring wasn't strong enough.) I suggest spray-painting this assembled component and the "front ring" part silver, or printing with silver material. You won't get a mirror finish like the housing, but wouldn't look as bad as it being another color. Mount the assembled adapter into the headlight housing pod, the hook on a catch at the top (this will make sense when you see it and how the original was installed) and the two screw holes aligned with holes at the bottom of the housing. Mount with self-tapping screws into the screw lugs. Use electrical tape around the edge of the LED headlight so light doesn't leak out through the gap between housing and front ring. Install the LED headlight into the housing adapter, with the lug fitting into the slot on the right side. Use four small self-tapping screws to install the front ring, holding the light in place. No provision for aiming the light is included in this part. Use a drill to enlarge or elongate the holes in the mounting bracket and tilt the entire headlight pod up and down to aim. Side-to-side aiming might be possible in this manner, but hopefully the bracket is mounted straight ahead, and LED headlights have such a broad beam that being a tiny bit off side-to-side shouldn't be a problem.