Buell Lightning headlight set-up

35684 Views 43 Replies 19 Participants Last post by Moto823, Mar 16, 2014

madmark33

Discussion Starter · Feb 4, 2009

I'm really interested in doing the whole buell lightning headlight assembly on my 03 sv650. I have a few questions that I haven't been able to answer after scowering the web for hours.

1.) Is there a good place to buy the parts, or do I have to hunt on ebay and stuff? I Haven't found a single online Buell dealer that has the stuff I am looking for online.

2.) What is necessary for fitting it to the stock sv forks? I am assuming I will need to make custom brackets of some sort. I have plenty of experience with metal forming and I have a full metal shop at my disposal with cnc and anything else you'd want/need.

3.) What are my options for the gauges? I know I can't retain the original cluster, so what are some good alternatives?

4.) I've never switched gauges on a cycle before so I don't know exactly what is all invovled. Any input from past experience would be appreciated.

Thanks for any help

1 - 20 of 44 Posts

raab02

· #2 · Feb 4, 2009

I haven't done the mod, but am looking into as a possible future mod.

I think you can order the lights/flyscreen from any Harley dealer.

Also, I think the stock headlight brackets from the nekkids will work with PVC spacers.

lnmcas02

· #3 · Feb 4, 2009

Hello,
I did this mod to my 00' naked a few years back

1) Ebay is definitley your best friend here. Although the parts can be had from a Harley/Buell dealer for relatively cheap. When I inquired it was around $180 for everything.

2) If you have a naked you can utilize the stock headlight brackets. You just need to cut a couple pieces of 1/2 in PVC tube to span the gap between the headlight bracket and the Buell headlight unit.

3) As for guages, I went with an acewell unit and it works well except the tach is a little jumpy. There are others as well such as trailtech, vapor, etc...I've also seen some use their stock guages by lowering/moving them in with custom brackets.

4) Most kits come with detailed instructions to hook them up. If you have even a little electrical experience you should be ok.

I actually made money doing this mod! I bought everything on ebay for $125 and sold my stock guages/headlight for $450!

Feel free to PM me if you need any help.

Here she is:

See less See more

madmark33

Discussion Starter · #4 · Feb 4, 2009

thanks! I've been searching ebay like crazy but I haven't found much. Those headlight assemblies must be hard to come by. I had no idea everything would fit up with the stock brackets. That makes things much more simple.

tk1971

· #5 · Feb 4, 2009

5

Here's mine. I'm able use my stock naked gauge, bracket and even keep the back gauge cover too. I'm using the stainless clamps for the bracket (sold by a fellow SVR Luis in the For Sale section), and I just crudely cut/drilled some aluminum extension pieces to get the right angle for the front screen.

There's enough room behind the windscreen for an HID ballast, so my low beam (right) is HID, and the original H4 connector connects to the highbeam (left).

It's a fun project.

tk

See less See more

madmark33

Discussion Starter · #6 · Feb 4, 2009

where did you guys get your lamps? ebay or a dealer?

xnoahx

· #7 · Feb 4, 2009

http://forum.svrider.com/showpost.php?p=975573&postcount=4
This is a good writeup with part numbers. Prices have changed though and the headlamp from buell is $116 now and the windscreen is $71 now. You can order from any Buell dealer or go online to www.chicagoharley.com and order them at 20% off.

yashuone

· #8 · Feb 4, 2009

hey tk1971!
what is that rear stand?
where'd you get it?
how much?

cool looking, never seen one.

tk1971

· #9 · Feb 4, 2009

madmark33, I got the lights and screen off of the SVR For Sale section from other members.

yahsuone, that is a $36 Harbor Freight motorcycle spool stand. It's like $45 and they keep sending me 20% off coupons. Works great.

For the headlights, I'm using 1.5"L x 3/4"D stainless pipe as spacers between the stock naked bracket to the Buell light.

Also there is a hole at the bottom of the Buell light that is not threaded. I tapped it with an M6 x 1.0 pitch so that I can have a 3rd point to secure the light so it doesn't move. I made a stainless bracket (long piece of metal with a hole on one end and a slot on the other) to secure it to the bottom triple. This is not in the pictures, but I thought I'd mention it, since I find that no matter how much I tighten the headlight, it'd still move.

tk

yashuone

· #10 · Feb 4, 2009

nice...

madmark33

Discussion Starter · #11 · Feb 4, 2009

Thanks for the thread link xnoahx. For some reason I can never get the search engine to work well on this site. I figured there must've been a post in the past about this, but i didn't find it.

bettysurf14

· #12 · Feb 18, 2009

Hey, just wanted to let you guys know that I just ordered my headlight set-up from St. Paul H-D and they gave me a 15% discount for everything. Here are the part numbers that they told me I needed:

Y0721.6AC - xbs headlight
M0023.1AJAYT - grille
M0645.1ADA - headlight mount
AA0404.11CVB - screws x2
B0613.1Z - washers x2
M1600.1ACMW - midnight black windscreen (can be other color too)
AN1005.3FSS - screws x4
CB0009.02A8 - washers x4

If anyone is interested in ordering the set-up just call Nils or Tim at 651-264-8939 (they are the internet sales guys for parts).

;D

See less See more

NeverEndingNinja

· #13 · Feb 18, 2009

What was the total?

DarkMatter

· #14 · Feb 18, 2009

I'm gonna say $165. Just a guess.

raab02

· #15 · Feb 18, 2009

Also, what's the best way to relocate the stock S gauges?

bettysurf14

· #16 · Feb 18, 2009

NeverEndngNinja said:
What was the total?

Crap sorry, here were the quoted prices they gave me:

Y0721.6AC - xbs headlight $98.00
M0023.1AJAYT - grille $35.00
M0645.1ADA - headlight mount $22.00
AA0404.11CVB - screws x2 $1.00 each
B0613.1Z - washers x2 $1.49 each
M1600.1ACMW - midnight black windscreen $60.00
AN1005.3FSS - screws x4 $2.40 each
CB0009.02A8 - washers x4 $0.80 each

snis300

· #17 · Feb 21, 2009

can you keep us updated bettysurf14

DarkMatter

· #18 · Feb 21, 2009

bettysurf14 said:
Crap sorry, here were the quoted prices they gave me:

Y0721.6AC - xbs headlight $98.00
M0023.1AJAYT - grille $35.00
M0645.1ADA - headlight mount $22.00
AA0404.11CVB - screws x2 $1.00 each
B0613.1Z - washers x2 $1.49 each
M1600.1ACMW - midnight black windscreen $60.00
AN1005.3FSS - screws x4 $2.40 each
CB0009.02A8 - washers x4 $0.80 each

that was discounted?

Stamford

· #19 · Mar 5, 2009

What year buells do these parts come off of? I am going to start looking for used but need the basic info first. Thanks!

bettysurf14

· #20 · Mar 5, 2009

According to the Buell guys the headlight is the same from 2003 to present.

1 - 20 of 44 Posts

This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.