|Things Are Looking Up!|
What's more, after having removed the original headlight and bucket, I fiddled around with everything and managed to get my bike started again! So lesson learned! Well, kinda... now the headlight won't work but there you have it people, always have a proper wiring diagram in front of you when doing this kind of thing and don't forget to label everything. It isn't fool proof, but it is idiot proof! ;-) In order to install this particular kind of headlight (RefinedCycle HDLT5-1) you will require the following bits and bobs:
- Phillips Screw Driver
- Allan Keys
- Scotch Tape
- One Pen
- Plastic Bag
- Three Bolts (as they are NOT included with the HM1 Mount or HDLT5- 1 Headlight from RefinedCycle - Cheeky in my opinion!
- Lock Tite (Blue)
Unscrew the bolts securing the original headlight.
With Scotch tape and a pen label each wire with a number.
(or something of your choice)
Remove rear bracket that supports and protects rear wires.
Remove nuts with a spanner or ratchet.
(Sounds like a man's worst nightmare, n'est pas?)
Once old headlight bucket is free begin feeding wires
through hole at rear of bucket.
Remove bucket completely and place somewhere safe.
Do NOT lose this rubber grommet! You WILL need it again!
Feed primary wire harness through the hole in the center of the lower triple tree.
Depending on what kind of new headlight you have purchased you will NOT
be able to re-use this hole again!
Secure your wires properly and place inside a bag
or other waterproof device.
In this instance I taped the bag thoroughly around the neck of each cable
and later placed my bike under its waterproof cover.
This worked just fine for me!
Take your new headlight and prep it for modification!
In this case I removed the inner headlight, rings, and mount supports.
You can use either the Rubber Grommet
or the Original Headlight for this step.
Cover or place grommet where you want to drill.
When you are satisfied on location mark it with a Sharpie Marker.
Colour in area with Sharpie Marker. Correct where and if needed .
Begin Drilling. Drill the entire area until you have the shape and size required/
I do not have a file but if you do it would be worth smoothing out the details.
As you can see it isn't the prettiest hole but the size was just perfect!
Place the rubber Grommet from the original headlight bucket
to the NEW headlight bucket! As you can see, it is a perfect fit.
Check inside to ensure that the Rubber Grommet is also secure and fitted properly.
As you can see it looks pretty darn nice.
It gives the new bucket a sense of factory 'fitted'
Remove the bulb and housing unit from both the new and old headlight.
As you can see they are pretty much identical.
No Soldering Required!!
The NEW headlight accepted the old headlight housing unit.
However, at this point I installed a new high intensity white light bulb.
Insert and secure old headlight housing unit into NEW headlight.
The original Rubber headlight rubber grommet installs directly over the new headlight rear.
The NEW wiring harness is next to the NEW headlight.
I am actually pleased that I did not have to solder or replace the original one.
Reassemble the NEW headlight bucket.
The mount supports are perfectly aligned with the rubber grommet!
The mount support screws are perfectly aligned with the screw.
Voila. Ready for installation on the motorcycle.
Install RefinedCycle HM1 headlight mount and bucket support.
You will have to buy the required bolts to support these two items
from your local hardware store or motorcycle shop.
Attach and secure NEW headlight bucket.
Once attached, prepare headlight for wire installation.
I found it easier to move the new headlight bucket forward.
Step back and admire your handiwork!
I spent $$$$'s since October getting the bike mechanically and aesthetically ready for the season. Keep in mind, I bought this bike from a gentleman who was the original owner. He had placed 32, 900 km on the bike since 1996 (when he bought it new) and had not ridden it in two years time! Thus, the bike has had a battery of things done to it including but not limited to:
- Full Tune Up/Service
- New Tires - Front & Back
- New Brakes - Front & Back
- New Battery
- New NGK Spark Plugs
- New Air Filter(s)
- New Oil Filters
- Oil Change - Shaft, Fork and Basic
- Brake Fluid Change
- New Fork Seals and Dust Seals
- New Kick Stand Kill Switch (waste of money as the original worked - the mechanics were incompetent at Moto-Sport Newman!)
- New Jardine Fishtail Pipes
- Re jet of Carbs in lieu of new pipes.
- New Electrosport Voltage Regulator Rectifier
- Certification with the SAAQ - Mandatory in Quebec after being off of the road for two years!
- Installation of Jardine Backrest extension
- Installation of Corbin Dual Tour Saddle
- Refined Cycle Headlight and mount
- Wild 1 Z Bars with Gran Turismo grips
In short, if your looking for a cheap cruiser with multiple customization options the Suzuki Intruder could be for you! Being shaft drive, it is virtually maintenance free and it has all the power you could possibly want from the 1400cc engine that is as torquey as it is fun and relaxing to ride. There are various examples of people bobbing these bikes out ranging from something relatively mild (as what I have done) to the extreme whereby the bike has been chopped and boasts a Mad Max appeal with a raked out front end that would give Orange County Choppers a run for their money!
Having stopped production of this particular model (also known as the S83) in 2009,the Suzuki Intruder 1400 is slowly but surely becoming a classic in its own right. A nice alternative to the Harley-Clones, you cannot go wrong with it; so if you ever come across one of these bikes for sale go for it! You'll be pleasantly surprised! Ride Safe!