Tutorial: How to Change the Headlight Bulb

[SpudRider]

While I am awaiting the arrival of the upgraded, LED headlight, I removed the stock HS1 bulb, and installed a brighter, H4 bulb in my RX3's headlight. I am very pleased with the light pattern, and the extra illumination the H4 bulb projects on the road ahead. :)

Here are the steps I followed to change the bulb.

Slightly loosen all the windshield bolts, so you can tilt the windshield slightly for some clearance with the headlight. EDIT: This might not be necessary, if you are willing to wiggle the headlight a little to coax it out from behind the windshield. ;)

Remove the two bolts at the side of the headlight. Note the alignment of the headlight with the bracket; this will affect the elevation of the light beams.

Pull the headlight assembly out from underneath the windshield.

Holding the headlight assembly so it does not fall, disconnect the wiring plug by pressing down on the tab.

Remove the nine bolts from the back of the headlight assembly, and open the headlight assembly.

http://i85.photobucket.com/albums/k70/morco46/headlight_zpsc620c3f9.jpg

Remove the plug from the bulb.

Remove the rubber boot surrounding the bulb.

Twist the the bulb retainer counter-clockwise, and remove it.

Remove the HS1 bulb.

Install the H4 bulb. It might be necessary to flatten two small projections on the mounting plate of the bulb to allow the bulb to sit flat against the mounting plate of the headlight.

Repeat all of the above steps in the reverse order to re-install the headlight.

I borrowed the disassembled headlight photograph from Katflap. Thanks, mate. :)

[SpudRider]

I have added a link to this tutorial in the Zongshen RX3 (ZS250GY-3) Modifications & Maintenance thread, which is pinned to the top of this forum. ;)

http://www.chinariders.net/showthread.php?t=14228

[SpudRider]

I know at least one RX3 owner has expressed concern regarding the extra heat generated by the 55W/60 H4 bulb. So far I haven't noticed any problems using the hotter, brighter bulb. However, if one is concerned the extra heat might damage the plastic reflector, he can always drill a few well-placed ventilation holes in the back of the headlight. :)

The headlights of all my other motorcycles are completely open in the back. Also, as you can see in the photograph, nothing inside the RX3 headlight will be damaged by a little dirt or moisture. ;)

[AZRider]

I'm not a physics major, but wouldn't air movement provide sufficient cooling to prevent overheating? Works for Harleys. Also, it's an incentive to ride, ride, ride. :tup:

[SpudRider]

I agree. Most people don't run the headlight very long when the bike is not moving. Also, the glass area of the headlight is very large, and dissipates a lot of heat. I haven't noticed any problems so far, and I don't think I will encounter any problems. However, if one is concerned, he can easily drill a few ventilation holes in the back of the headlight. :)

[No1Vic]

Think I'll be following your headlight upgrade route Spudrider with a brighter H4 bulb, I did fit a HID bulb kit but it meant cutting the back of the headlamp housing to get it back together so pulled it out. Glad to see your write up on the LED bulb, I would have tried one but like you need to see more to the sides illuminated not just in front.

[katflap]

http://attachments.motorfans.com.cn/2015/04/08/oxC5LlEvs5089.jpg

Getting one of these bulbs from taobao :lmao::lmao:

( feel free to delete post)

[Adjuster]

^^^^I like it^^^^ Looks very Star Trek

[SpudRider]

Getting one of these bulbs from taobao :lmao::lmao:

( feel free to delete post)

Now that is an LED headlight. :)

:lmao:

[Weldangrind]

That's clearly going to need some protection, or it just won't last.

[JTHSPACE]

I noticed it's a right hand twist, they are going to need the left hand one for the U.S. otherwise it will dip the wrong way.

[detours]

I was in the auto parts store and saw an H4 Silverstar Ultra on sale ... and remembering Spud's review of the light distribution of the stock headlight vs the LED, I decided to buy one and try it out in the RX3.

I'm aware of the potential heat issues, so I'll keep an eye on the temps.

The swap was easy ... although I don't know why Zonghsen used NINE screws on the headlight assembly! I went for a ride tonight and the difference was amazing ... so much light! And the high beams lit up everything!

Now, I've used Silverstars before and they have a limited life. They're also sensitive to vibration, so I may kill this light early. But if I do, I'll just replace it with a standard H4 halogen. Meanwhile, I won't be afraid to ride the RX3 at night anymore!

[SpudRider]

Indeed, the stock headlight with an H4 bulb does an excellent job illuminating the road. After switching to the H4 bulb, my RX3 now easily has the best headlight of all my motorcycles. :tup:

After riding almost 7,500 miles, I have noticed some potential discoloration of the headlight reflector. Therefore, I cut a hole in the back of the RX3 headlight assembly so it is large enough for me to change the light bulb without having to remove the rear cover. I also placed a small hole at the bottom of the headlight assembly to allow for water to escape.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/GEDC0620_zpsnp8utdyc.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/GEDC0620_zpsnp8utdyc.jpg.html)

The hole in the headlight assembly also allows heat to escape the headlight easily, helping to prevent any possible damage to the reflector from using a light bulb with higher power. ;)

[keithmaine]

Great tips spudrider

[DaytonaMike]

Spud I think its been a while since you did this modification. How is it holding up? Any issues? Anything you would do differently? Do you still recommend this mod and the removal of so much of the back housing?

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20RX3/GEDC0620_zpsnp8utdyc.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20RX3/GEDC0620_zpsnp8utdyc.jpg.html)

[SpudRider]

Spud I think its been a while since you did this modification. How is it holding up? Any issues? Anything you would do differently? Do you still recommend this mod and the removal of so much of the back housing?


This modification is working perfectly. The headlight housing is very robust. I have not had any problems whatsoever, and I'm confident I won't have any problems in the future. I would not do anything differently. I am glad I made the hole this large. In addition to keeping the reflector cool, the large hole makes it much easier to change the light bulb. :)

[DaytonaMike]

Sorry, another thought..how often do you ride in the rain or is water intrusion into that space not an issue? It appears water can get in there easily either riding in the rain or when washing the bike. Is that an issue? Can it cause any problems if water gets inside that space? I know you cut an additional hole at the bottom to allow drainage but is there anything in that space thats prone to problems from water? Sorry for all the questions but I really would like a brighter bulb and an easier method to change it but want to be careful with long term durability of the mod. Thank you!!

[SpudRider]

The space behind the headlight is well protected by the windshield and the bike's frame. I wash my bike with a garden hose, and I don't get any water in the headlight. Most dirt bike headlights are open in the back. In fact, the headlights of my other 4 motorcycles are open in the back, and I have never had a water problem with any of them. ;)

However, if you are uncomfortable with the mod, don't do it. ;) You should know that I did see some bubbling/distortion of the top of the plastic reflector after using the H4 bulb without a ventilation hole.

[rd1959]

How big is the ventilation hole?

[AZRider]

How big is the ventilation hole?

Check the photo below.

[rd1959]

Oops. I was under the impression that in addition to cutting out the back you were talking about drilling vent holes in the back of the reflector too.