Plastic headlamp and halogen bulb?

I've found a replacement globe in halogen with the correct base for the Kinlon, an H(S)2 Phillips at 35 watts but as I have plastic 'glass' in the headlamp it will get too hot and melt apparently, from what I have read. Would it be OK to simply drill air holes in the metal headlamp casing or would the cool airflow blow the globe? I don't think rain or splash water will get in if I position the holes right at the top front and at back bottom for air flow - because the plastic shroud should stop that (hopefully). Any thoughts?

As a by the way, a single replacement indicator globe cost me $9.95 locally! Grrrr. Things are quite expensive in Country Australia I think!

I'd refrain from drilling holes - it's not just the ambient environmental heat that a halogen generates that disturbs (polycarbonate) plastic lenses, it's also the focused heat of the light source that does the damage and sometimes not just to the lens. If your headlights internal mirror finish is the wrong type of plastic it too can become tarnished, and should the bulb itself sit inside a type of metal flange then that also can suffer from a burnt tarnish. That being said, I don't think 35W is a particularly huge issue, as usually the halogen bulbs affected are 100W plus. I use several 'illegal' (not for legal road use) 135/100W in my Suzuki & my Yammie Dragstar also had 135/100W halogens before I fitted the HID system. I also have fitted 100/80W halogens without a relay in my Jetmax and it uses completely polycarbonate plastics, and I've not had any issues. I know when I was back in NZ, the auto accessory dealer did warn me about any halogens over 100W burning out polycarb lenses when I bought the 135/100W... however he was talking to the converted... I used to run Hella Rallye 2000 pencil & wide beam spots years ago... on my rally car, which I'd love to have here, as most oncoming traffic drive with high beams on as though they are permanently wired on at night. That's not a major in my Suzuki, but when I'm riding two wheels, the glare it just down right dangerous. I'd luv those Hella Rallyes' to light up the offenders quick smart.

Thanks BD. I might just try one and see then! A pretty cheap assembly anyway on the Kinlon so nothing much to lose; if I have to replace it I can go for something better with a ballast resistor, fuse etc., whatever is required. The beam at night seems fine as it is on open roads, until you go above 60 kph or so, then you just can't see enough ahead and that is when the big 'roos jump out onto you! From your experience, would the beam spread be the same? I need ideally a wider spread too because of those critturs sitting in amongst the roadside trees on narrower roads near home; I had thought the spread was designed into the front glass so I might need a different unit anyway?

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Originally Posted by jape

Thanks BD. I might just try one and see then! A pretty cheap assembly anyway on the Kinlon so nothing much to lose; if I have to replace it I can go for something better with a ballast resistor, fuse etc., whatever is required. The beam at night seems fine as it is on open roads, until you go above 60 kph or so, then you just can't see enough ahead and that is when the big 'roos jump out onto you! From your experience, would the beam spread be the same? I need ideally a wider spread too because of those critturs sitting in amongst the roadside trees on narrower roads near home; I had thought the spread was designed into the front glass so I might need a different unit anyway?

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No worries, I think your idea of giving it a go, is the right attitude. I can relate to the roos... I circumnavigated OZ twice once in a ford escort van that had been completely customised into a wee panel van (yep, complete with a bed in the back, storage cupboards and all) - bought that one in Mandura out of Perth. The next circumnavigation was in a Ford Falcon XF wagon... and both times I drove both and at night in the outback, and the roos were thick as the vegetation on the sides of the roads and tracks... scary stuff. About the spread, it's a combination of the glass/polycarbonate lense and the reflecting mirror.

Amazing mate! Back in the 80's? Not all tarmac back then! I envy you, never got around to that dream. Might do it after China. Easier these days in a courier type van with aircon and GPS.

I remember a trip I did in the early 80's in a girlfriend's dad's restored 1968 Toyota Crown (faultless luxury back then), just a few thousand KM across from SA to Sydney and back and that was a heck of a drive for a Pom used to 'long' trips of a hundred miles ... when I got into the desert at night, there were 'roos every twenty yards which exhausted me. They didn't hop away, just sat there and even hopped toward the lights! I quickly realised why 'bullbars' were essential especially when I had to help a shocked shiela from a volvo with a huge red roo kicking its death throes on her lap after destroying the hood and screen on its way to smashing into her! I had to cut its throat to finish it off and drag it through the screen to release her because she was trapped in the seat-belt under it and it was thrashing around with two broken legs and its guts in her face - then she complained about the blood everywhere ...

Unfortunately we can't fit bullbars on m'bikes so good lights are essential. I shall try the halogen and keep my fingers crossed, might ask the 4WD workshop in the next town about wide beam options/fuses/2nd battery etc. Or just chicken out and only travel during the day, I've had too many heartstopping shocks on the 'bike with 'em.

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Originally Posted by jape

I had to help a shocked shiela from a volvo with a huge red roo kicking its death throes on her lap after destroying the hood and screen on its way to smashing into her! I had to cut its throat to finish it off and drag it through the screen to release her because she was trapped in the seat-belt under it and it was thrashing around with two broken legs and its guts in her face - then she complained about the blood everywhere ...

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Jeez,and I thought getting puked on this week was bad...I don't think I could have handled that kind of mess.

Cheers!
ChinaV

Nah mate, yours is far and away the top story, something special about flying vomit :puke:
whereas blood and guts is, just blood and guts! Moral of the story, always carry a sharp knife ...

Actually she did puke after, but missed me by a few yards :icon10:.

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Originally Posted by jape

I've found a replacement globe in halogen with the correct base for the Kinlon, an H(S)2 Phillips at 35 watts but as I have plastic 'glass' in the headlamp it will get too hot and melt apparently, from what I have read. Would it be OK to simply drill air holes in the metal headlamp casing or would the cool airflow blow the globe? I don't think rain or splash water will get in if I position the holes right at the top front and at back bottom for air flow - because the plastic shroud should stop that (hopefully). Any thoughts?

As a by the way, a single replacement indicator globe cost me $9.95 locally! Grrrr. Things are quite expensive in Country Australia I think!

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35W should be no problem, jape. Fireman Mike was running 60W in the Qlink XF200 headlight. That doen't even have any vents at all and he said he wasn't having any problems. I'm running a 45w through mine with a different headlamp. I have two vents and I took out the running light. The lens gets hot but hasn't melted. I want to move up to 60w next year and I don't think that I will have a problem.

Hi Jape,
Just reading about headlights in your post.Thought you might be interested in my experience.My commute is 40km daily, 30km of which is rural, with occassional roos and foxes to avoid.The standard RT200 headlight is pathetic, unsafe at over 70kph.I have fitted a H.I.D. 35w headlight which is much, much better..and provides safe illumination of the road ahead, up to the top speed of the bike.
First, I visited a wrecker and forked out $10 for a headlamp off an early Honda CB250...it fits straight in to the Kinlon headlamp shell.(Without measuring, I can't be certain, but at a glance of the new Honda CB125 passing in the street, the headlamp looks to be the same diameter as the Kinlon.)

The H.I.D. unit I used, cost just $35 on E-bay and is very good quality, completely sealed and with excellent connections.It was listed as 6000k H4 High Low Beam Bi-Xenon Motorcycle Super Bike HID Conversion Kit.The seller was 'rateme5'. Cheers, xxx