Issues with halo fitment

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Eric1109

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I am trying to install my halo and light. It seems that the gap between the halo ring and headlight is to big. The bolts and thick washers don't reach the bucket on both sides. If i bolt it onto one side it is totally off center, and the other side cant reach (image 1). As you can see from pictures. If i hold it not attached it seems that everything is the correct size (image 4). I cant imagine there were different halo and headlight sizes. headlight bucket is S version with amp hole, and 7 inches. is it as simple as bending in the ears that are on the side of halo ring, and two little rods to make everything fit. Or am i missing something.
 

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There are 2 spacers. Depending on headlamp style there are various part numbers. I think the one for the original "S" model is 061234. easy enough to measure the gap and turn up a couple if you know someone with a lathe.
 
I measured the gap. It’s close to one inch on each side. yet the spacers are 1/2 inch. I think you are right I need to have a couple turned.
 
1" seems like a lot. Mine are more like 9/16". Could that be an after market Halo? I have a made in India one that looks beautiful but the dimensions are crap. Got an old O.E.M. unit and had it re chromed.
 
Eric1109 said:
I am trying to install my halo and light. It seems that the gap between the halo ring and headlight is to big. The bolts and thick washers don't reach the bucket on both sides. If i bolt it onto one side it is totally off center, and the other side cant reach (image 1). As you can see from pictures. If i hold it not attached it seems that everything is the correct size (image 4). I cant imagine there were different halo and headlight sizes. headlight bucket is S version with amp hole, and 7 inches. is it as simple as bending in the ears that are on the side of halo ring, and two little rods to make everything fit. Or am i missing something.
Click to expand...
Seems like the halo is not OEM. AFAIK, the 5/16" (BSC/CEI) bolts that go through the halo, mounting, and into the headlight shell are 1-1/8" long. The spacers should be between 1/2" and 9/16" (don't remember the exact size).

As I remember it, there is a small gap all the way around between the halo and headlight shell when assembled - MUCH less than you have.

Does your headlight shell take 5/16" bolts and are the slots in the halo and mounts meant for 5/16" bolts? What is the inside diameter of the halo?
 
Could be its not an original halo. I might have one of those india ones . Came with the bike so not sure on its provenance.
Yes the bolts are 5/16. i have the correct spacers, but still leaves over 1/4 gap on each side. I guess easiest is to get some thicker spacers made up. Unless I try to find a different halo
 
Eric1109 said:
Could be its not an original halo. I might have one of those india ones . Came with the bike so not sure on its provenance.
Yes the bolts are 5/16. i have the correct spacers, but still leaves over 1/4 gap on each side. I guess easiest is to get some thicker spacers made up. Unless I try to find a different halo
Click to expand...
Expensive, but available: https://andover-norton.co.uk/en/shop-details-2/15581/headlamp-support-ring-s-type-

Assuming you have longer mounting bolts to test, put it together with the spacers and several 5/16" washers on each side and make sure it all works. If so, then longer spacers will work.
 
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