Exploring the Unknown

Exploring the Unknown

Thursday, May 31, 2012

Installing a RefinedCycle HM1 Mount & HDLT5-1 Headlight

Things Are Looking Up!
As mentioned in my previous blog, Installing Wild 1 Chubby Outlaw 10 Inch Z Bars & Harley Vintage Gran Turismo Grips, I found myself at the end of the experience with a beautiful bike but no way of starting it! So after crying about it for twelve hours or so I decided to get a start on rectifying the problem the very next afternoon and took the headlight apart again. Only this time, I figured I'd also start on installing the brand new RefinedCycle HM1 Mount Adapter & HDLT5-1 Headlight I had purchased some several months ago. As always I had waited so long because of no other reason than a genuine lack of confidence. However, the more I take this bike apart the more I find myself wanting to take everything apart just to see if I can put it back together! ;-) I decided to prep by getting everything I required including a soldering kit, which inevitably would not be necessary! Suffice it to say, there is something extremely satisfying about working on your own bike; even more so when you complete the job and realize you didn't get ripped off from some shop who has a penchant for over charging -  an epidemic amongst some shops in Montreal!

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:

  1. Phillips Screw Driver
  2. Allan Keys
  3. Scotch Tape
  4. One Pen
  5. Plastic Bag
  6. Three Bolts (as they are NOT included with the HM1 Mount or HDLT5- 1 Headlight from RefinedCycle - Cheeky in my opinion!
  7. Lock Tite (Blue)
  8. Drill
I managed to get the bucket off and rewired everything (without new headlight attached) in less than an hour! As for installing the new headlight I had to modify the new headlight bucket first! So that had to wait until this morning. By taking your time and being patient you will find that you and a monkey's uncle could get this job done. So without further ado, let's have a look at the step by step process on how to install and modify a new headlight:

Step 1:
Unscrew the bolts securing the original headlight.

Step 2:
With Scotch tape and a pen label each wire with a number.
(or something of your choice)

Step 3:
Remove rear bracket that supports and protects rear wires.

Step 4:
Remove nuts with a spanner or ratchet.
(Sounds like a man's worst nightmare, n'est pas?)

Step 5:
Once old headlight bucket is free begin feeding wires
through hole at rear of bucket.

Step 6:
Remove bucket completely and place somewhere safe.

Step 7:
Do NOT lose this rubber grommet! You WILL need it again!

Step 8:
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!
Step 9:
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!
Step 10:
Take your new headlight and prep it for modification!
In this case I removed the inner headlight, rings, and mount supports.

Step 11:
You can use either the Rubber Grommet
or the Original Headlight for this step.
Cover or place grommet where you want to drill.

Step 12:
When you are satisfied on location mark it with a Sharpie Marker.
Step 13:
Colour in area with Sharpie Marker. Correct where and if needed .

Step 14:
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!
Step 15:
Place the rubber Grommet from the original headlight bucket
to the NEW headlight bucket! As you can see, it is a perfect fit.

Step 16a:
Check inside to ensure that the Rubber Grommet is also secure and fitted properly.

Step 16b:
As you can see it looks pretty darn nice.

Step 16c:
It gives the new bucket a sense of factory 'fitted'
Step 17:
Remove the bulb and housing unit from both the new and old headlight.

Step 18:
As you can see they are pretty much identical.
No Soldering Required!!

Step 19:
The NEW headlight accepted the old headlight housing unit.
However, at this point I installed a new high intensity white light bulb.
Step 20:
Insert and secure old headlight housing unit into NEW headlight.
The original Rubber headlight rubber grommet installs directly over the new headlight rear.

Step 20a:
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.

Step 21:
Reassemble the NEW headlight bucket.

Step 22:
The mount supports are perfectly aligned with the rubber grommet!

Step 23:
The mount support screws are perfectly aligned with the screw.

Step 24:
Voila. Ready for installation on the motorcycle.

Step 25:
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.
Step 26:
Attach and secure NEW headlight bucket.

Step 27:
Once attached, prepare headlight for wire installation.

Step 28:
I found it easier to move the new headlight bucket forward.

Step 29:
Feed ALL wires through the rubber grommet at the back of the headlight.
Unfortunately this is a small bucket and
what took twenty minutes to finish the  day before took over an hour.
My hands were TOO big to adequately move around inside the bucket in order
to attach the wires inside. Visibility is dark back there as well, so have a helper with a flashlight if possible!

Step 30:
Once all wires are connected attach the headlight itself and insert into bucket.
Secure headlight with rings that are included with the headlight.
I managed to get everything done inside an hour and a half, but again, that is due to the awkwardness
of the size of the bucket and my hands.

Step 31:
Secure all bolts and align headlight properly so that maximum visibility and effectiveness is obtained.
Tape any visible wires with electrical tape and secure appropriately.
Nota Bene:
The original wire harness has been re-routed to the right side of the bike as visible in the picture.
Step 32:
Step back and admire your handiwork!
I still have to reconnect the headlight properly but as mentioned above, the bike starts fine now. I actually purchased a Haynes Manual for the Suzuki Intruder yesterday and it arrived today! All in all, the experience was great and as mentioned above, the pleasure of actually working on your bike cannot  be overstated enough. It's a great way to spend time with little helpers, such as my son, whilst also learning the inside out of the motorcycle that you trust every day to get you from point a to z. The new headlight was the last thing I had purchased that needed installation... at least for now. ;-)

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:

  1. Full Tune Up/Service
  2. New Tires - Front & Back
  3. New Brakes - Front & Back
  4. New Battery
  5. New NGK Spark Plugs
  6. New Air Filter(s)
  7. New Oil Filters
  8. Oil Change - Shaft, Fork  and Basic
  9. Brake Fluid Change
  10. New Fork Seals and Dust Seals
  11. New Kick Stand Kill Switch (waste of money as the original worked - the mechanics were incompetent at Moto-Sport Newman!)
  12. New Jardine Fishtail Pipes
  13. Re jet of Carbs in lieu of new pipes.
  14. New Electrosport Voltage Regulator Rectifier 
  15. Certification with the SAAQ - Mandatory in Quebec after being off of the road for two years!
  16. Installation of Jardine Backrest extension
  17. Installation of Corbin Dual Tour Saddle
  18. Refined Cycle Headlight and mount
  19. Wild 1 Z Bars with Gran Turismo grips
  20. etc...
Thus far the bike has been ideal for modifications despite initial concerns that, like the Yamaha Virago for instance, it would be limited to just a few basic cosmetic changes. However, the Suzuki Intruder 1400 has proven to be as versatile as the Harley-Davidson Nightster I owned back in the Republic of Ireland. For instance, despite being listed as 7/8, when I swapped the bars out for 1 inch I have not had to change the controls or throttle sleeves! They fit perfectly! The same can be said about any purchase I have made for the bike.

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!


  1. Great effort! Thanks,


  2. ... very nicely documented - very helpful.

  3. super!!!! very helpful! nice looking bike...

    1. Thanks very much! Hope you get yours installed without any headaches! :-)

      I am very satisfied with the headlamp. It was well worth the investment and time to take to install myself. :-)