Cyclops replacement LED headlight bulb kit for Teneres

greenwall

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Yes, it certainly seems to be the heat. I had my right side LED bulb out checking on the problem and was amazed the amount of heat being generated in only several seconds that it was on. I am going to call again before I put in the new ones and ask about drilling 1/4 inch hole in the bottom of the caps as was recommended for my tiger 800 when I had them in that bike. As long as the hole faced down nothing seemed to get in there while I had them. I don't know. They probably would have recommended it if they felt it was a good idea. Can't hurt to ask though.
 

WJBertrand

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greenwall said:
Yes, it certainly seems to be the heat. I had my right side LED bulb out checking on the problem and was amazed the amount of heat being generated in only several seconds that it was on. I am going to call again before I put in the new ones and ask about drilling 1/4 inch hole in the bottom of the caps as was recommended for my tiger 800 when I had them in that bike. As long as the hole faced down nothing seemed to get in there while I had them. I don't know. They probably would have recommended it if they felt it was a good idea. Can't hurt to ask though.
Though drilling a hole in the bottom will allow water to drain, I think it will still admit dust. These bikes are often used in dusty off-road conditions. Eventually that dust will get all over the entire inside of the headlight lens and reflector. Some kind of redesigned cap that would place the fan outside the housing would seem to be the ultimate fix.
 

SilverBullet

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WJBertrand said:
...Some kind of redesigned cap that would place the fan outside the housing would seem to be the ultimate fix.
??
If the bulb is sealed inside the housing and the fan is outside how is it going to cool it? If that were the case airflow alone would be enough to cool it.
 

greenwall

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WJBertrand said:
Though drilling a hole in the bottom will allow water to drain, I think it will still admit dust. These bikes are often used in dusty off-road conditions. Eventually that dust will get all over the entire inside of the headlight lens and reflector. Some kind of redesigned cap that would place the fan outside the housing would seem to be the ultimate fix.
Yes, I know about the dust concern. But that is what Cyclops recommended for my Triumph and I never had any problems with dust in the housing. Also, The actual opening in the Tenere's headlight housing where the bulb sits is quite small. Just big enough for the bulb to slip in in fact. This may be part of the problem. The caps themselves cover a much larger are that also includes the area around the projecter lenses (I think). I would have to open it back up to make sure, but I was a bit surprised how tight it was. I know you have LED bulbs, but I had forgotten how it all went together in there since I last had it open. I too, was thinking about an exterior fan that sucked the heat out through a small tunnel or something. But that is not for me to design and market. Anyway, that was why I made my comment in an earlier post about LED/Halogen bulb replacement not being sorted out yet. With most vehicles switching over to LED it will probably become a moot point in a few years.
 

WJBertrand

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SilverBullet said:
??
If the bulb is sealed inside the housing and the fan is outside how is it going to cool it? If that were the case airflow alone would be enough to cool it.
Well the fan would of course remain connected to the bulb base! What I imagine is some kind of rubber seal that would allow the fan to project out of the cap yet keep the interior of the headlight sealed. My Honda ST1300 has a seal that fit around the base of the bulb but left the connectors exposed. Perhaps the seal I'm imagining would seal the bulb adapters? The bulbs would then need to fit to the adapters with an additional seal, usually an o-ring or similar. Not sure if the Cyclops bulbs are designed this way but my recollection is that they are not, so a different design bulb might be needed. I've seen some LED lights with removable/replaceable fans that might allow an opportunity to create a seal around the base between the bulb and the fan.
 

Gigitt

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Here is my Cyclops 3000lm LED bulbs mounted with a rubber boot (boot has 2 wings - lights are top and bottom) - you can see the back of the fan with the word LED - the Drivers are the disc things tied up.
The boot was cut so it would fit behind the plastic bulb holder. Bulb then slips through from the back and the bulb holder was then put on from the front.
My bike live outside this is fully waterproof and has been on for over 25,000 km.

Doing something similar for a S10 would probably mean reversing the rubber boot and slipping the boot into a custom 3D printed cap from the front. This would bring the bulb closer to projector mount... it would require some finesse to do this - so it all lines up and still allows some boot movement for when you need to adjust your headlights.
 

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Ramseybella

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The LED lamps i installed today i cut a hole in the rear of the dust cap so just to let the fan housing stick out.
Then i ran a bead of Silicone between the fan housing and the dust cap.
The way i figure it if it burns out the silicone will just peel off anyway when you pop the cap off.
I didn't buy Cyclops LED's..
 

WJBertrand

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Ramseybella said:
The LED lamps i installed today i cut a hole in the rear of the dust cap so just to let the fan housing stick out.
Then i ran a bead of Silicone between the fan housing and the dust cap.
The way i figure it if it burns out the silicone will just peel off anyway when you pop the cap off.
I didn't buy Cyclops LED's..
Have you got a photo? Love to see this mod.


Sent from my iPhone using Tapatalk Pro
 

Ramseybella

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WJBertrand said:
Have you got a photo? Love to see this mod.


Sent from my iPhone using Tapatalk Pro
I don't know the diameter of the Cyclops fan housing but these are G9 and it fit right to the edge.
I didn't take my time making measurements just kept removing material till the fan just squeezed in without binding to the ID of the hole.
The connectors i found a happy place for them to cram into. If the Cyclopes has a larger plug end you may have to mod the cap to run it outside.
For now i have 65k Ferry light, it's better than the Standard halogen, reaches out a little more but did this because i was tired of dumping money every year or twice a year on a set of $40.00+ halogens.
I admit my night vision has turning to crap it did pickup some Mule Deer on the side and in the road last night's test ride in the mountains.
I also had my crash bar LED's running as i always do.
I may buy something brighter or a different color more natural down the road but if these prove to be more economical that's fine with me.
The H7 plate comes off the LED so you can snap the clip retainers on first then twist and lock in the lamps.
If you have a Dash infill it needs to come off, i have squeezed my hand in under the board to replace a bulb a couple times but it took some flesh with it. :'(



Need to clean some of the extra silicone Spooge off it you have to do the finger smear when it's all assembled, but who's looking? :-\
 

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Madhatter

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twinrider , don't panic , the latest failures is on two bikes , mine is one of them .... and its not a complete failure , one diode . so still getting light from bulb. the other guy ( I forget his handle ) one diode also. the bulbs you have ordered are new and improved according to cyclops , so your bulbs may last a long time.... its hot here in Texas and LEDs don't like heat, not sure how big an issue it really is ( ambient air temperature ) but should be cooler in Japan.
 

Madhatter

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another thought is that each bulb is 65.00 , not much more money than a single halogen that will not a year.... headlights should not be this hard ...... since Edison first bulb they should have it down by now.... one more question , why switch from HID to LED ... I almost did the HID but choose LED because it seemed safer....
 

Ramseybella

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Madhatter said:
another thought is that each bulb is 65.00 , not much more money than a single halogen that will not a year.... headlights should not be this hard ...... since Edison first bulb they should have it down by now.... one more question , why switch from HID to LED ... I almost did the HID but choose LED because it seemed safer....
I wanted to try LED for $25.00 i think so far i did OK, even though i had to drill a hole in the caps for the fans..
Tired if dumping money on bulbs every six or eight months.
I do keep a spare in my kit bag.
 

twinrider

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Madhatter said:
one more question , why switch from HID to LED
I had HID on my Gen. 1. This is a completely different bike. I had zero issues with the HID, but the LED install is considerably easier so that's the main attraction.
 

Madhatter

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seeming complexity (cause I'm a bit lazy) will send me the easy route every time... how is the dust, moisture , situation with the caps drilled Ramseybella ?
 

Ramseybella

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Should be good as i stated slathered some black silicone between the fan housing and the caps.
Has to be better than some guys not installing the caps and claim to have no issues with dust or rain.
Besides it's been a week so far nothing funny going on. :-\
 

Madhatter

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since I have an extra set of caps , may be the way to go..... fans are a great idea , but electric motors even tiny ones generate heat , so in my thoughts in an enclosed space as in the tenere head light housing it has to raise temperatures .
 

Ramseybella

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Madhatter said:
since I have an extra set of caps , may be the way to go..... fans are a great idea , but electric motors even tiny ones generate heat , so in my thoughts in an enclosed space as in the tenere head light housing it has to raise temperatures .
Helps if they are round fan housings, as you just make a hole. The tighter the better to make a less messy seal with the silicone sealer.
They get hot indeed the cooling fins do OK dispersing the heat but the fan is what pulls the heat away.
My plugs are butt up against the cooling fins crammed behind the caps, just wondering if they are high heat resistant plastic?
I just blindly went at it with the WTHell attitude and drilled away fitting the fan housing until it slipped into the hole. :p
 
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