So... motorcycle headlights suck. Especially "old school" round headlights.

Since the headlight on the Hyosung was really badly busted up to begin with, I figured it might be a good test mule for me to try something fun.

So I took the stock housing which was made of cheap Korean plastic and I cut the back side out of it, where it would normally hold a standard H4 bulb. Did I mention the housing was beat up? Don't mind the JB-welded-back-together plastic lens. Here you can see the Valeo projector low beam unit I sourced from a busted up headlight housing from my A4. The headlight broke off all it's tabs when I hit a deer but the projector was ok so I kept it around for just such an occasion. Also notice it is a low beam housing, see the steel cutoff inside?

I kept machining the headlight housing opening with a few bits in my dremel tool until I opened it up just right for the projector housing flange to sit nice and flush into it.

I drilled and tapped the plastic headlight housing to accept some M6x1.0 hardware. Then I screwed the projector to the housing, having applied a film of silicone sealant to the flange for extra support and to keep moisture/dirt out as much as possible.

  1. No picture of the original bars on the bike unfortunately but you can see, this is what came off.
  2. Tape on the bar to keep the worn out bagged out throttle housing from turning (it still turned easily).
  3. Floppy, terrible clutch perch and lever. Even though the perch is square to the bar, see how much flop is in the lever. Oh and the nub is broken off the end.
  4. This throttle housing was terrible, floppy, loose, faded... not at all adequate for controlling the whopping 20ish hp on tap.
  5. The backside of the housing and the sacked out cable.

I picked this gem up a couple years ago. I hadn't had a street bike since I started racing in 2006, but while in Europe on a 2 month trip I had rented a bike to ride around Spain for a few days after having watched the MotoGP at Valencia and seeing how nice the roads in the area were. I got a Hyosung GT250 Comet as my rental bike and spent a few days tooling around on it. For a small displacement, and cheaply made bike, it was actually very nice. The main thing that I liked was the fact that the bike was basically a 650 chassis, but with just the little 250 motor in it. Which meant that for a taller rider like myself, it was a very comfortable riding position, unlike most small-displacement bikes that are so skinny and short, that they feel really cramped. The other thing was that the full-size frame meant it was full-size weight, which you might think would be a bad thing but in fact it is a bonus for ride quality as it is much more stable over bumps in the road than it's smaller competitors. The inverted forks were mushy but did a decent job, the full-sized tires it had were a big bonus, as the larger-than-most-250s size meant that good rubber was cheap and plentiful for the bike. The motor was actually decent for a 250, accelerating to a respectable 150kph, smooth, and sounded decent thanks to the V-twin layout. It also got astonishingly good fuel economy in the 3L/100km range and had a nice big tank, meaning range was upwards of 300km to a tank, much better than the 120-150km range of a supersport. I saw a lot of potential in the bike at the time, so when I got home I kept my eyes peeled for a deal on one, thinking it would make for a nice cheap street ride and would be a really decent ride with a few tweaks, all the while remaining very cheap to insure and operate.

This bike came along in the spring of 2012 as Rider's Training Institute in Toronto cleared out some of their fleet of school bikes. For a mere 1500$ I got this sweet ride, complete with worn out clutch, worn out and broken levers, broken headlight, broken tail, and a bunch of other school-related problems.

I started out by going through the bike and doing routine maintenance, making the best of what was already on the bike. I then shod it with Dunlop Q2 tires (replacing the Cheng-Shin buns that were on it), and much to my surprise the bike was actually fairly decent to ride. I spent the rest of the summer riding it on track at Calabogie and Shannonville, using it when coaching was needed, or just to go for a rip when it pleased me. The Dunlop Q2s actually turned the bike into a respectable track bike, easily out-carving most intermediate riders on modern supersports.

The first upgrade that summer was to remove the stock internals from the forks and replace the fork springs with kit Kawasaki 0.85 straight rate springs, and the compression and rebound valve stacks and piston were replaced with stock kit from a 2007 CBR600RR. This made a huge difference in the bike, which now had a front end that was totally planted. Everything else was still garbage, but with good tires and forks, the bike was now well into the 2:30 laptimes at Calabogie, which is very respectable with only some 25 odd horsepower on tap.

In the fall of 2012 I left on a road trip around North America, threw the bike in the back of the truck, and brought it with me, it was to be my fun excursion toy while on vacation! I rode it in San Francisco, Los Angeles, San Antonio, and all the way up the Florida Keys to Key West, the bike was a great ride every time!

Now since I have been back from my trip I have been using the bike on the streets around home every now and then, and the little ineficacies of the bike have started to bug me, so I'm now on a mission to improve it!

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