Zongshen 200GY-2 H4 Headlamp Conversion

[SpudRider]

As with most Chinese motorcycles, my Zongshen Sierra 200GY-2 came from the factory with a 35W/35W BA20D headlamp bulb. Seeking to get more visibility at night, I soon switched to a 45W/45W BA20D bulb, after I had converted my taillight, brake light, turn signals, and indicator lights to LEDs.

http://chinariders.net/modules.php?n...ewtopic&t=8157

I have been running the 45W/45W incandescent bulbs for about a year, without causing any problems to my Zong’s electrical system. Since my headlamp burns continuously, the bulb filament gets hot, and the vibrations produced by trail riding can hasten the failure of the filament. Halogen bulbs burn much hotter than incandescent bulbs, and since I frequently ride my motorcycle in the dirt and gravel, I chose incandescent bulbs because I knew they would endure the vibration better than the hotter, halogen bulbs. However, as I have continued to ride more aggressively, even my incandescent bulbs are failing faster than they did previously.

Although I had bought a good supply of the 45W/45W bulbs, I realized the BA20D headlamp bulbs would be much more difficult to purchase, should they fail while I was traveling away from home. Therefore, I decided to convert my headlamp to accept a bulb that could be more easily purchased at Wal-Mart, or any automotive parts store.

I remembered that the BA20D bulb holder for my Zong had 3 tabs, much like an H4 headlamp bulb. :idea: I also remembered reading that many KTM riders had converted their headlamps from BA20D bulbs to H4 bulbs. Therefore, I began my research on the internet to find more information. However, I did not realize at the time that all H4 bulbs are halogen bulbs! Searching the internet, I soon discovered that many KTM riders had melted their plastic headlamp lenses after converting to the hotter, H4 halogen bulbs. 8O

However, I am pleased to report that my Zongshen Sierra 200GY-2 employs a metal headlamp reflector, with a glass lens. Therefore, I decided to convert to the brighter, H4 halogen headlamp bulbs.

Researching some more, I discovered the following thread, which describes converting a BA20D bulb holder to an H4 bulb holder.

http://www.xrv.org.uk/wiki/index.php...ght_Conversion

Looking at my Zong’s headlamp assembly, and researching even further, I also realized that my Zong headlamp assembly was designed to accept a proprietary, Honda 45W/45W, PX43t-65 degree H4 bulb, instead of the standard P43t bulb! :? To see the difference between the P43t and PX43t-65 degree bulb flanges, read the last post in the following thread.

http://www.vfrdiscussion.com/forum/i...howtopic=54520

To get a regular, P43t bulb to seat into a P43t-65 degree connector you can use adapter shims, or you can cut the bulb holder to accept the conventional tab arrangement.

http://www.casporttouring.com/store/...tegory_Code=El
http://webpages.charter.net/bpeloquin/H4mod.html

Ordinarily, if you don’t use either of these two methods, the bulb will not seat evenly, and your headlight will not be properly adjusted. :?

http://webpages.charter.net/bpeloquin/H4tilt.html

Searching the China Riders forums, I also found the following thread, posted by “thatboatguy.”

http://chinariders.net/modules.php?n...ewtopic&t=3516

This thread confirmed that the Zong headlamp unit would accept H4 bulbs. Therefore, I went to my local CarQuest store, and bought a 3-prong, H4 socket/pigtail assembly for $4.10, part #S526. I also ordered twelve H4 halogen bulbs for $32.31, delivered, from Light Bulb Emporium.

http://www.lightbulbemporium.com/eik...6ek_01009.asp#

After the H4 bulbs arrived, I removed the Zong's headlamp bulb holder from my motorcycle, and replaced the original BA20D socket with the H4 socket. I then began to experiment with different ways to mount the H4 bulb into the Zong’s headlamp assembly. After a bit of cutting and experimenting, I reached the following conclusion. To properly mount an H4 bulb in the Zong headlamp assembly, don’t cut the bulb holder, and don’t use shims!

Instead, merely trim away the small “dimples” on the bottom of the H4 bulb flange, opposite the large, central tab. Then mount the H4 bulb the very same way you mounted the original BA20D bulb assembly unit! With the small “dimples” removed, the H4 bulb will mount securely, and almost perfectly level!

In the photograph below, I have my Eiko H4 bulb mounted in the headlight assembly, ready to be reattached to my motorcycle. You will notice that I cut away a large portion of the bulb’s bottom flange as I experimented with different mounting arrangements. However, cutting away the flange is not necessary. You merely need to snip away the small dimples at the bottom of the flange, as shown inside the yellow circle on the other H4 bulb shown in the photograph below. Snipping the dimples away allows the H4 bulb flange to seat evenly, without hitting the small hook on the metal reflector that secures the bulb retaining clip.



If you puchase the Eiko H4 bulbs from Light Bulb Emporium, you can have a halogen, H4 headlight for $2.69! Also, if your headlamp bulb extinguishes away from home, you can now easily find a replacement bulb.

I just finished installing the H4 headlamp bulb in my Zong. As I gain more experience using the Eiko H4 halogen bulbs I will report on their nighttime illumination properties, and their ability to endure vibration.

Spud