Hyosung GT250R headlamp removal

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

hello guys,
just passed my test and i've had my bike for a few days now and was riding home other night when the headlight stopped working, it flicked on and off a few times and has now stopped working altogether!

anyway, got a volt meter and there is 12v on the terminals (not easy to get to) so it must be bulbs or the unit itself.... does that sound about right??

has anyone ever got the light unit out, looks like i will have to try as there isnt much room to see anything, possibly get bulbs out but not going to be easy with the light unit in situ. looks like the whole top fairing will need removing??

any advice would be appreciated, been loving the bike, just a shame its off the road now Sad

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--Current Bike: '98 Hornet CB600F
--Previous Bikes 2012 Hyo GT250R - 2010 YBR125 - Back in '91:Suzuki 50cc moped & Honda CB125T Superdream Laughing

--CBT -Feb '11, Theory -Nov '11, Mod 1 -Jan '12, Mod 2 Feb '12

Fairies attack · Banned Joined: 21 May 2011 Karma :

If you remove the front cowling, there will be 4 black 13mm bolts holding it in.
Remove them and you will be left wit the unit and clocks.

Not to hard to do just looks a bit tricky with all the wires in there.

Check the head light relay, it should be under the front seat, they are all the same apart from the flasher relay which is the big one on the left.
Change the head light one with the fan one and see if you have the same problem.

Anything else just PM me.
I have the GT650r and they are pretty similar.

pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

bikenut · World Chat Champion Joined: 21 Nov 2011 Karma :

hi dude, i think there is an online manual for this bike on this site.

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

ok, so today i managed to get some time to have a look at the headlight.

i'm not sure its possible to change the bulbs in these headlights with the front fairing in place, so this is what i did, from what i can remember.

1. remove the 6 screws around the instrument panel and remove the panel.

2. remove the bottom bolts holding the front fairing in position (see bottom screw in pic below) leave top ones in but loosen.

3. remove all the screw holding the front fairing to the side fairing, 3 each side.

4. remove the nuts holding the indicators to the fairing frame

5. remove the allen bolts holding the mirrors in place.

6. remove the top 2 bolts holding the fairing in position (top ones in pic below)

7. remove the front fairing.

whilst i was at it i took the side fairings off, these will come off in one piece and can be wriggled out under the bike.

https://i1102.photobucket.com/albums/g458/Cheerfulgrin/bike%20pics/Hyo%20GT250R/IMAG1006fig.jpg

https://i1102.photobucket.com/albums/g458/Cheerfulgrin/bike%20pics/Hyo%20GT250R/IMAG1025.jpg

the lamp holders and the common wire spring mounted type, but there is little room for manouver.

https://i1102.photobucket.com/albums/g458/Cheerfulgrin/bike%20pics/Hyo%20GT250R/IMAG1019.jpg

there are more pictures from this job in this album so have a browse if you like.

the wiring all looked in good condition, although it needed tidying up, there is a rubber boot type thing that wraps around the connectors, so put some tape round that to be on safe side.

i've tested them and they now work, so pleased with that, just got to put the fairings back on tomorrow, time beat me today!

bulbs are 12v 55w H3 for dip lights
12v 55w H1 for main beam
you can get these in any car spares shop.

given the fairings a good clean, filthy inside and underneath, and touched up some small scuffs here and there, painted the allen head bolts for mirrors.

looking forward ot getting it back in one piece and out for a spin at weekend! Laughing

____________________
--Current Bike: '98 Hornet CB600F
--Previous Bikes 2012 Hyo GT250R - 2010 YBR125 - Back in '91:Suzuki 50cc moped & Honda CB125T Superdream Laughing

--CBT -Feb '11, Theory -Nov '11, Mod 1 -Jan '12, Mod 2 Feb '12

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

Thank you for sharing that! , I am shocked that the whole fairing had to come off to change a headlamp bulb Sad

.

I will be going into the garage tomorrow to see if I can find a way of doing it without having to remove so much fairing.

I`ll let you know what I find?
____________________
I am the sum total of my own existence, what went before makes me who I am now!

st3v3 · Super Spammer Joined: 16 Oct 2006 Karma :

So does the light sit so flush against the fairing brace that it restricts you getting the bulb access cover off while the light is still screwed in its mounts?
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Roger wrote: Women don't get damp for clingy puppies. Get some better happy pills, hit the gym & buy a medallion the size of a dinner plate. Job done

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

st3v3 · Super Spammer Joined: 16 Oct 2006 Karma :

I'm surprised, I think for a bike like that it's rediculous to have such a small space.
____________________
Roger wrote: Women don't get damp for clingy puppies. Get some better happy pills, hit the gym & buy a medallion the size of a dinner plate. Job done

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

i thought i should update this, after having to replace the low beam lamp recently, i am pleased to report it was a ten minute (tops) job and i didnt have to remove a single piece of bodywork, lol Very Happy

____________________
--Current Bike: '98 Hornet CB600F
--Previous Bikes 2012 Hyo GT250R - 2010 YBR125 - Back in '91:Suzuki 50cc moped & Honda CB125T Superdream Laughing

--CBT -Feb '11, Theory -Nov '11, Mod 1 -Jan '12, Mod 2 Feb '12

hyogt250r · L Plate Warrior Joined: 02 Nov 2012 Karma :

Hello to all,

i was just wondering, how did you manage to remove the two bolts (one on each side) on the top fairing of the hyo....these bolts have the 'cross' type slots.....i have been trying but in vain, they are just too tightly screwed on.....is there anything extra you did to remove them?

Cheerfulgrin · Scooby Slapper Joined: 17 Apr 2011 Karma :

I used a small socket ratchet with a screwdriver head on it to remove the , mine came off without any trouble, but I've read other people have struggled with those 2 too.
____________________
--Current Bike: '98 Hornet CB600F
--Previous Bikes 2012 Hyo GT250R - 2010 YBR125 - Back in '91:Suzuki 50cc moped & Honda CB125T Superdream Laughing

--CBT -Feb '11, Theory -Nov '11, Mod 1 -Jan '12, Mod 2 Feb '12

hyogt250r · L Plate Warrior Joined: 02 Nov 2012 Karma :

thanks for the info...i'll give it a try....

mr-jermy · Nitrous Nuisance Joined: 17 Oct 2012 Karma :

if your trying to undo the screws and they are stiff try putting the screw driver into place and tap it with a hammer this sometimes helps to dislodge a stiff/stuck screw or bolt, has worked for me many times Smile

mrhall · L Plate Warrior Joined: 12 Dec 2014 Karma :

Hi guys i am new to this forum. So the story is a mate and I were replacing a handlebar on the GT650R and to get better access we took the headlight assembly off and while I wasn't looking a piece came out and my mate can't remember where it went. Does anyone happen to know where a hook that has a loop on one end is suppose to sit to stablize the headlight?

myutesux · L Plate Warrior Joined: 05 Jul 2020 Karma :

Hi All Can't we just take bolt Question

screws under the light horsing and get it out from they
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TROY PATRICK

myutesux · L Plate Warrior Joined: 05 Jul 2020 Karma :

I just did it can't be done any other way
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TROY PATRICK