Yamaha XSR900 - 7" LED headlight mount

cults3d

This is a prototype that has been on my 2021 XSR since 9/23/2021 and has been ridden over 100 miles without issue, so far. I will add more details if I find it necessary to revise this print. Edit - June 19, 2022: I'm currently at over 2,200 miles with this ring mount installed with no issues. Making a print in PLA and leaving it in the sun does deform it a bit, but has not altered function. I also printed a version in PETG, but have not felt the need to swap it out. I had originally started on this design because drop-in LED headlight conversion kits for XSR900s are between $400 to $900. Add $100 for a 7" conversion kit. Beyond that, the other option is to replace the entire housing with a $30 - $50 bucket and put an LED headlight in it. However, this requires some cutting of the bracket under the original bucket and some cable management. The inside of the XSR900 bucket is already neatly cable managed and I wanted to retain that. There are a lot of options out there for replacing the headlight, and I wanted to come up with the simplest option, especially for a 7" LED headlight. Overall, if you bought a 3d printer, filament, the LED headlight and the bolts necessary for this project, you'll spend less than some drop-in replacements. And you'll have a new 3d printer for other projects as well, with filament to spare. 3d model: This print will mount a very specific 7" LED headlight to the OEM XSR900 bucket. Yamaha XSR900 owners will know that the OEM headlight is a 5.75" reflector with a halogen bulb. I had originally set out to print a bracket and ring to mount a 5.75 inch LED headlight into the OEM bracket, but the cost of a 5.75" and a 7" LED headlight are basically the same, and a 7" headlight seems more fitting for the size of this bike. After measuring the OEM bucket (180mm around), I decided a 7" could easily fit at 177.8mm, without looking too awkward. Headlight: The LED headlight model used is the Wisamic 7 inch 80W Motorcycle LED Headlight. I purchased the LED headlight on Amazon. https://www.wisamic.com/products/7-inch-led-headlight https://www.amazon.com/Wisamic-Motorcycle-Headlight-Compatible-Fatboy-Black/dp/B01M63N6PJ Specific details: This LED headlight model has 10 screws in the front which mount a plastic ring to keep the front lens attached to the headlight body. Please be careful removing this ring as there is a weatherproofing sealant that prevents water from entering the lens/headlight. I replaced my headlight screws to be black, but this is not necessary. If you are rough with the threads, however, you may need to get slightly longer screws as they will strip easily. The screws used to mount the headlight & mount to the bucket must be replaced with 40mm long, 4 or 5mm screws. My screws measure 4.8mm x 40mm. I purchased these screws with washers and nuts from Lowes and hot glued the nut inside of the protruding mounting bump inside the bucket. Use locktite on the nuts and they will be secure. Only 2 bolts hold the mount in place (same as OEM), along with the included "bracket" (UB) model. This bracket is optional, but recommended; It will help with alignment for installation. The bracket model has a cutout for the OEM mounting latch on the upper portion of the bucket lip. I simply super glued this bracket in place, flush, inside the printed headlight mount. Do not glue this to the lip so that it would protrude outside of the mount. It must be glued inside, on the first step up. It can be glued on the upper or lower part of the inner step, but gluing to the top will make it difficult to remove the mount in the future. Printing 2 brackets to glue top and bottom will provide the most stability, but you will not be able to remove or install the headlight into the mount afterward. Parts needed: 3d printer that can print over 192mm (the final print measures 192 x 188 x 57) [My printer is an FLSUN SR (Super Racer)] Wisamic LED headlight (link above) 2x - 4mm x 40mm screws, any thread 2x - washers 2x - nuts for the screws Superglue (optional)