How to Install a Headlight on a Yamaha PW80
The Yamaha PW80 is a small motorised dirt bike designed for young riders between the ages of seven to 10. This is a great starter dirt bike to get youngsters used to riding. Unfortunately, these bikes do not come equipped with a headlight or a lighting coil.
However, it is possible to purchase a headlight assembly and lighting coil and install them yourself. There are several different headlight assemblies on the market that will fit the Yamaha PW80, and each comes with its own detailed wiring instructions.
Purchase a headlight assembly kit from an auto parts store or online. Also purchase an internal or external lighting coil since the Yamaha PW80 does not come factory-equipped with one.
Hold the headlight assembly against the front part of the Yamaha PW80, just below the handlebars. Make sure the light is level. Use a permanent marker to mark where you need to drill the screw holes that will hold it in place then set the headlight aside.
Attach a drill bit that is one size smaller than the screws or bolts that came with the headlight assembly. Drill holes in the marked locations, just far enough to punch through the outer plastic covering.
Position the headlight assembly so the drill holes match up with the holes for the screws or bolts. Hold the headlight in place with one hand.
Attach a screwdriver or socket drill bit to the end of the drill. Tighten the headlight assembly screws or bolts until they are snug but do not over-tighten them to avoid stripping the screw holes.
Lay out the wiring diagram for the headlight and follow the directions carefully. Each manufacturer has different wiring directions, but the headlight will come with a diagram and detailed instructions so you can properly hook up the wiring for the headlight. This will involve attaching the internal or external lighting coil during this part of the procedure.
Use zip ties to secure the wires to the PW80. Make sure there is no extra wiring sticking out or rubbing anywhere and ensure that the silicone rubber connector boots and connectors are all firmly in place.
Follow step 1 from above.
Mount the headlight to the PW80 with the rubber straps that came with the headlight assembly kit. Just wrap or stretch the rubber straps around the handlebars or fork tubes, whichever works best for your headlight assembly.
Follow Steps 6 and 7 from above.
- "PW80 Owner's Manual"; Yamaha Motor Company; 2009