Recently I fitted one of my PC800's with an LED headlight bulb. It's really fantastic. And for sale right here. So now it was time to fit the other one with one as well so that my riding partner also has the joy of seeing things more than half a mile away.
Since that other bike has been maintained by someone with a lesser grasp on how fragile plastic is and that it is really important not to use crappy Chinesium bolts and screws, I decided to make a small tutorial with the other one. This one has had a way better service history and you can notice that in handling but also by the fact that it has mostly all its original bolts, nuts and screws still.
But anyway, let there be light!
Unscrew these three screws and place them somewhere safe. Next, carefully remove the cover. SHould not take too much effort, but this stuff is old and brittle, so be careful.
Unplug the connector. Do remember that the middle contact is always on top. Same goes for the seat of the bulb. One pin up, two pins downwards like the Mercedes star. Also, inspect the connector. As you can see, this one suffered a bit.
Pull the rubber cover off by pulling on the tab. Be careful here. Stuff is old. Please note that there is a TOP marking. When you are going to refit the rubber, TOP should point upwards.
Unhook the clip that holds the bulb in place. This is a bit of a finicky job and this is the easy bit. Trust me, you will growl while trying to fit this clip back in.
Place your finger where it says clip and move it according to the blue line. The red line indicates the shape and direction of the clip-finger-putter-onner. \@_@/
When you have retrieved the bulb, you're now ready to detach the seat of the LED bulb. This is actually a super handy feature. Simply give it carefully a turn and you can slide it right off.
Take a close look at the seat, it needs to go in with the rim on the outside.
Place the seat of the bulb in the headlight unit, with one pin up and the other two downwards to the side, like a Mercedes star. Also, there is a cutout (indicated in red) that needs to be at the bottom. Can't miss, especially with the help of my super fancy MS Paint skills.
Tip: You can actually get quite a clear view of what's going on on the inside by looking through the lens. MAKE SURE that the seat is flush and evenly seated.
Now we have come to the moment of reseating the clip that holds down the bulb seat. It's probably just me, but I'm always messing around with this and then getting cramps in my legs or hands because of the awkward position you have to assume.
Make sure that both prongs of the clip (it's kinda U-shaped) are properly aligned. Then put your finger on the teardrop-shaped finger-putter-onner and move it according to the green line. The red line indicates how the tear-shaped thingy should be when it's clipped in correctly. Have fun!
Now it's time to put the bulb into its seat and that's quite easy. Be careful, it's still a kinda fragile product. When facing the headlight, insert the bulb in the hole of the seat with the wire sticking out on the left, horizontally. Jiggle it a little until it sits well. Now, rotate the whole unit slowly counter-clockwise until it snaps in and does not want to turn any further. Do not force things. It should be a smooth process. Insert the bulb carefully in the hole and slowly turn it. If you have done it correctly, the TOP TWO LED strips should be closest to the lens.
Connect the original connector to the connector of the LED bulb. Make sure it sits snug and does not fall out. When you switch on your light, you should see a pyramid shadow in the center bottom when you look straight into the light. You'll live, it's not like you're watching into the sun. If the pyramid is in the top like I had it initially, you will blind oncoming traffic and they will hate you for it. So:
I've been driving for many miles now with this bulb and it's awesome and it also keeps working. Quite an important thing for something you buy in China. If you want this bulb as well, go buy a set through the link at the bottom of THIS page. You will then sponsor the website that needs a few bucks for hosting and the purchases of documentation and licenses. Thanks! <3