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Norick Abe YZR-500 Replica

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The spiritual successor to the RD-350

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95Racer: 95bhp and 95kg

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Norick Abe YZR-500 Replica

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The spiritual successor to the RD-350

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YZR-500 Frame Kit

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The spiritual successor to the RD-350

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Single headlight conversion

This idea developed soon after I got my hands on the Yamaha YZF-R125 fairing set. I always liked the single, asymmetric headlight look that is common on endurance racebikes. It will also help to give the bike its own identity away from the YZF-R125.

This meant filling in the left hand side headlight. I started with simply putting 3 layers of fibreglass over the original headlight. After it cured, I trimmed the fibreglass layup to fit the headlight opening and used a bit more fibreglass to bond it in place. Here is a picture of the partially finished, single headlight, nose cone. It needs a bit more filler and sanding before it is ready for paint.

 

So, after looking at this closely, a bit of work is required. First, the headlights on the YZF-R125 both use a single filament H7 bulb. So in addition to filling the hole on the fairing, eliminating one of the headlights will mean converting the other one into a dual filament, hi-lo beam, H4 bulb configuration. And lastly, the ZX-6R switch gear of the ZX-6R front end, like most late model bikes, has day-time running lights, meaning there is no "off" switch, only a hi-lo beam switch. Since both lights use the same bulb, the beam difference of high and dipped beam must be accomplished in another way.

Studying this a bit more, it turns out that only difference is the location of the filament inside the headlights. That is, the filament is 7 mm further back on the high beam side (left) compared to the dipped beam side (right). After measuring the filament locations of the H7 and H4 bulbs, it turns out that a 5 mm spacer on original low beam light will do the trick. The spacer will also convert the H7 fitting into an H4 fitting. Here are the H4 and H7 bulbs:

 

And here is the rendered drawing for the spacer, and then glued onto the back of the right side headlight.

 

Obviously, the wiring also needed to be changed but this I already incorporated into the new loom I made from scratch (see seperate post further down).