Moped Army

I thought I would pass this along. It seems to have worked out really well for me. Remember, this is for a 12v setup. Also, this fix works best with stock bulb mounts with the little metal piece that holds things into place. Read on...

Needed: (1) 9006 Halogen Bulb $6-$14, (1) 9006 Plug $2-$3 at any auto parts store, and electrical tape.

Tools: Dremel with cut off wheel and simple grinding tool.

First, buy a 9006 halogen bulb ($6 at harbor freight) and plug (maybe $3). You need the bulb with a 45 degree bend in the plug portion like this:

Here's another pic:

You also need a plug that fits this bulb:


Start with the part of your headlight that your bulb plugs into, like this (stock puch bulb mount):

I used a bullet headlight, so mine looks a little different than the one above. The key to this conversion is to dremel and cut your plastic bulb mount so that all metal and extra plastic is removed. The idea is that you are going to use the stock bulb mount to mount your new halogen bulb and keep it in place. You will want to cut and dremel out just enough material so that your bulb can fit into the stock one and all sits in place well. This is VERY important, because if these hot hot halogen bulbs get loose in your housing, you will get this (no good):

So anyway, after your cutting and dremel work, you want to end up with something like this:



Next, plug your halogen 9006 into it like so:


Now mount it to your headlight. If you have a metal piece that holds your stock bulb in, you're in luck. If not, you will have to find a good way to keep the bulb in place, such as crazyglue+baking soda. But this fix is for those with the little metal piece. See how beautifully it fits!:

Now tape it up real good:

Insert the plug into the back of the halogen:


Wire it up, yo!! One wire goes to the ground, the other goes to the stator/voltage regulator. You end up with something like this:


These halogens are super bright (55w - like daylight) and they do not burn out. I have a non-working voltage regulator, a 12 volt CDI setup, and I can't get the bulb to burn... no matter how high I rev! Hope this helps someone. Peace out.