Honda ATC 90 110 round headlight conversion, fix, retrofit

[trike savior]

here is an idea for you guys running the old 90 and 110 who have a broke or missing headlight lens. you do need the chrome trim ring (bezel) to do this. in my case I needed the 12 volt bulb but a 6 volt bulb can be made to fit this lens.

purchased a 79 110 recently with blown motor, had an 82 110 motor needing a chassis, so I did swap. had chrome headlight bezel but no lens, and since I would be converting from points motor (6 volt) to CDI motor (12 volt) I needed to make some changes anyways and this is what I came up with.

used this light from harbor freight, often on sale or use a 25% off coupon they are like 5 bucks
http://www.harborfreight.com/12-volt...ght-93904.html

removed the lens from case. it was almost the right size, just a little bit too small

I split some 1/4" fuel line in half length wise and put it on the headlight bezel (see pic) and this took up enough room to keep lens in place. easier and safer to do with a hook blade vs a regular utility knife blade

put the lens in place, then sacrificed an old coat hanger. cut 2 pieces a little longer so you can bend each end to grab bezel as in pic. needs to be a little more than a 90 degree bend on each end.

then mechanix wire the 2 hanger pieces together and you have a nice tightly secured lens

flip over and shave extra fuel line with a razor blade (found hook blade easiest) until it looks decent.

I have put this through some off roading and it held up through all the bouncing around I could throw at it. the strength of it will depend on the job you do.

this has a 12volt light bulb in the lens when you buy it but local auto store should have a 6 volt bulb you can make work. may require drilling the bulb hole bigger but it can be made to work.