Author Topic: Stock Headlight cheap fix  (Read 846 times)

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  • stanzthemann
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on: May 27, 2024, 11:36:21 am
Hey GT535 gang, Stan here.

Been facing the issue of a rusting headlight reflector ever since I got my bike and restored it, with all attempts of finding a replacement stock looking headlight turning up futile. (everytime I find one, it has the similar rusting issue  :P)
Efforts to find one new here in India has turned up pretty dry as well, as no one really seems to have any in stock currently! My search will go on tho ⚔

Meanwhile, driven by the need to not have a rusty looking headlight, while maintaining the retro look of the headlight glass,  I decided to experiment with existing retro style headlight units - and found a match with the Classic 350 UCE model headlight. Although it does not have the intense Fresnel look of the stock headlight, it fits and most importantly, maintains the retro look of the bike!

The headlight unit fits into the headlight housing ring, and you can install your choice of H4 headlight and parking bulbs. (be adviced, most LED headlight bulbs have a very focussed throw and may not suit those looking for wide beam coverage)

Hope this helps those looking to maintain the retro look of the bike (and don't really care about headlight brightness that much)  ;D

Onurag Chatterjee

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Reply #1 on: May 27, 2024, 12:40:15 pm
That's useful information!

Thanks for sharing!


  • Grease Monkey
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Reply #2 on: May 27, 2024, 01:57:46 pm
 Any type of 7 inch headlight reflector will fit, eg mahindra jeep, ambassador or even a Tata ace. The mahindra jeep and ambassador headlights can handle higer wattage halogen bulbs (100/90W). The reflective surface won't get dull due to higher heat.

Adrian II

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Reply #3 on: May 28, 2024, 12:04:09 am
Remember to check the dip pattern for whether you drive on the left or on the right if you buy a generic 7" headlamp unit.

Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...


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Reply #4 on: May 28, 2024, 03:30:15 am
The 7” Classic 500 and 7” GT 535 headlights and mounting rings are identical. There are many other classic looking 7” styles that are interchangeable…..very surprising to see rust….never had any on the OEM units.  “Adjure” brand makes some nice ones as well. Most of the current LED H4 bulbs will fit nicely and give you a substantial improvement in lighting.  Thanks.
« Last Edit: May 28, 2024, 03:55:53 am by GSS »
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  • Grease Monkey
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Reply #5 on: May 28, 2024, 02:04:00 pm
My headlight reflector was a mess (see the chrome peeling off in the photo). Instead of buying a replacement LED completeheadlight, I bought a STEDI LED high/low beam replacement with built in LED driver. It is a 'plug 'n' play' and all you have to do is unplug the halogen H4 plug and swap it for the LED one.

I sourced a new headlight shell for a reasonable price (AUD$57 from memory) and as the space inside it was tight, I had to tape the wiring to the inside of the hedlight shell to make way for the LED tower.
It fitted and now my yellow beam which looked like the glow from a couple of mating glow worms has turned into a white hot laser beam with great spread and also good penetration of complete darkness on high beam.
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