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Easy 1200s headlight improvement

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Post  allambiejohn Thu 27 Oct 2016, 10:03 pm

I often have to ride home in Metropolitan Sydney after dark.  I think I have the standard 1200s globes which lets face it are anaemic (especially the dipped beam).  Without resorting to new wiring or relays, what can I do to at least improve the standard lighting option? The full beam is OK but the "normal" lighting is so poor I have my doubts whether it is even on!
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Post  Chalkie Thu 27 Oct 2016, 10:20 pm

I have the same issue. Not wanting to add driving lights but would be interested if there is a simple solution.
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Post  BanditDave Fri 28 Oct 2016, 5:22 am

This topic has been discussed fairly extensively on this forum.

Firstly, the voltage drop between the battery and the headlight is the biggest issue.
Doing other modifications when you have low voltage is pretty much a waste of time and money.
Look on eBay for ready made H7 relay/wiring harnesses. I purchased a H4 harness for the VStrom for about $12.
These ready made harnesses are virtually "plug and play" and it shouldn't be very hard to find someone who will help you in exchange for some liquid refreshment.

You may find that improving the headlight voltage is all that is required however if not then installing HID or LED lights is the next logical step.

I have fitted HID lights to three bikes in the past and have been really happy with them.
Ideally you should fit purpose built reflectors but I never bothered and got an acceptable result in each case.
A 35watt HID light will give you 3 to 4 times the light of the standard 55watt filament bulb.
I suggest you consider the colour temperature when buying a kit. Anything from 4300K and less than 6000K will give you a very white light. Above 6000K the light will have a blue tinge which is quite noticeable by the constabulary and may result in a financial donation.
I found it necessary to angle the headlights down slightly so as not to dazzle oncoming motorists.
I also found that I rarely used high beam even on rural roads due to the performance of the HID on low beam.
A HID light kit should cost around $50 on eBay although there are much more expensive ones available if you so choose.

I have not used LED lights. My main concern is that the units I saw had little fans to cool them. I wonder what would happen if these fans were to fail.
I also could not find LED lights with a colour temperature below 6000K.

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Post  Chalkie Fri 28 Oct 2016, 7:36 am

Thanks Dave, I'm a complete blonk when it comes to these things but am able to follow up your recommendations now - all power to the Forum! Very Happy
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Post  Ironman Fri 28 Oct 2016, 5:08 pm

1st check the voltage at the bulb connector vs at the battery terminals whilst enging running.
If its okay another very common issue is the securing hardware loosens in the projector lens assembly. This generates alot of black dust due to vibration and this likes to adhere to the lens thus reducing the transparency. Also this loosening of hardware inside the headlight assembly can stuff up the headlight aim.






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Post  BanditDave Fri 28 Oct 2016, 7:17 pm

I agree with IronMan.

The problem is inherently poor design which results in voltage drop or crap within the headlight assembly.

The point I would make is that you need to sort out the basic issues before venturing in to new technology (HID/LED) unless money is no object

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Post  allambiejohn Fri 28 Oct 2016, 8:14 pm

Cheers for the advice.  I have to admit I was hoping the answer was  'just bin the globes and fit brand X' sort of solution!  But I'll certainly check the voltage and assembly for dust as a first step - that I think even I could do.
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Post  Ironman Fri 28 Oct 2016, 8:25 pm

search you tube for
Suzuki Bandit 1200S Head Lights cleaning

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Post  Handy1250FA Tue 01 Nov 2016, 6:53 am

If it's not a voltage issue and you are looking for a very simple upgrade, just change the globe like I did. 

I can certainly notice the difference.

I used the "Narva plus 120" (they make a "plus 130" now too)
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Post  allambiejohn Tue 01 Nov 2016, 7:49 pm

Cheers for that, haven't had a chance to test the voltage yet.  It looks like a bit of a pain to get to the bulb holder in the first place.  I did however notice the presence of the dreaded black dust around the lens.  Not sure I am ready to put bits of my bike in the oven though!  I'll have to wait for a totally free weekend before I try that.
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Post  gus Tue 01 Nov 2016, 9:44 pm

Back in the gs days I would simply change the 55\65 (? ) globe to a 65 \100 (?) Numbers may be a little out, but you get the idea . Fit a relay though .
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Post  Re-Cycled Tue 01 Nov 2016, 9:51 pm

If everything else is good then the Philips Extreme Vision globes make a worthwhile improvement, also had a good +90? Narva globe that was in fact branded Osram on the metal ring.

Easy 1200s headlight improvement Philips-Xtreme-Vision-130-H7-Headlight-Bulb-Twin-At-PowerBulbs-1

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Post  Ironman Thu 03 Nov 2016, 4:29 pm

Its easy to fix the headlight. I did it over a weekend. Just don't cook the light of forget you put it in the oven. Set it to just under 100 degrees and check on it like an expectant father in a birthing suite.
Once you clean the lenses and reflectors and locktite all the projector screws put it all back together and recheck the light performance. If still not to your liking, check voltages at the bulb connector.
If okay then go for the bulb upgrade. Cheapest fixes first, then work your way up.

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Post  mtbeerwah Thu 03 Nov 2016, 11:09 pm

Hi mate, I might suggest you get an owners manual, just to familiarize yourself with the bike.

Do some home work first, before you start ordering bulbs, and relay kits.

The low beam,  is an HB4,
The high beam, is an HB3.

I don`t want to see you order wrong parts, then find out they won`t fit.

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Post  allambiejohn Sat 12 Nov 2016, 2:56 pm

So I checked the voltage

12.45v at the battery and 12.33 at the bulb connector.  I think I may have found the root issue though, there  should be 4 tiny screws which hold the whole lens assembly to the headlamp unit.  My driving light has none, the damned thing has been held in place by only the bulb connection ! Easy 1200s headlight improvement Img_1710

So this is what is should look like -  with studs AND screws (the blurry silver blob).

I have this:

Easy 1200s headlight improvement Img_1711


No screws and you cant get to the screws without separating the unit.

Fire up the oven - I'm going in !
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Post  allambiejohn Sat 12 Nov 2016, 3:00 pm

So, lets imagine I successfully separate the unit and get to the screws etc without ending up with a blob of molten plastic.  How is the unit sealed again?  Do I clean off the old sealant and use a silicone sealant from Bunnings or is there something special required?
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Post  allambiejohn Sat 12 Nov 2016, 6:54 pm

So far so good - Thanks Ironman for the oven instructions.  It came out and separated fine. Blimey there was a lot of dust.  The full beam lens and reflector were as clean as a whistle, the low beam was full of dust. Here they are as they came out of the oven, I have wiped my finger across the low beam lens to show the dust. Gave the whole thing a clean and what a difference it made. An added bonus was the 4 missing screws were stuck to the butyl seal ! Have decided to use the oven again to loosen up the seal to rejoin the 2 halves- it looks like there is plenty of sealant so this should work.
Easy 1200s headlight improvement Img_1712
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Post  allambiejohn Sun 13 Nov 2016, 9:34 pm

Sorted!

Thanks everyone for your help.  The difference is incredible - and this is with the same bulb!Easy 1200s headlight improvement Img_1713
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Post  Bosco15 Sun 13 Nov 2016, 10:40 pm

Great result. Good to see the forum advice in action. 
I did the same process, with help from the forum. 
The system works. 8-)

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Post  Handy1250FA Mon 14 Nov 2016, 9:00 am

Good job! well done.
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Post  Ironman Thu 17 Nov 2016, 7:44 pm

Great to hear!
did you put the "blinds" back into the projectors? Just curious.
Are you happy with the result to the point of not spending dollars on relays / bulbs / LEDs / arc reactor to improve night riding?

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Post  allambiejohn Wed 30 Nov 2016, 8:55 pm

Yeah I put the blinds back in - didn't want an issue with dazzle.  The results are pretty good and much better than they were, but would I consider an upgrade ?  Yes, if you can avoid becoming an issue for others better illumination is always going to be better.
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Easy 1200s headlight improvement Empty Headlight dust again

Post  allambiejohn Mon 02 Dec 2019, 7:43 pm

It has been almost exactly three years since I last cleaned out the headlight. Recently I noticed that the headlamp was taking on that anaemic glow worm look again so I repeated the oven trick. Here is the lens with after I had swiped my finger across it. Where does this dust come from? Looks like this is a three yearly chore !  


.Easy 1200s headlight improvement Img_2511
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