Upgrading the Yamaha XTZ750’s Halogen Headlights to LED: A Custom CNC-Made Bracket
The stock dual halogen reflector headlights on my Yamaha XTZ750 were outdated, inefficient, and not nearly as bright as I wanted them to be for nighttime riding. Since I’m rebuilding and upgrading my new (for me, at least) Super Ténéré, I decided it was time to replace the old halogen setup with modern LED headlights. This not only improves visibility but also reduces power consumption—a significant advantage on older motorcycles with limited electrical output.
Designing a Custom Bracket
Unlike some newer motorcycles where you can simply swap out the headlight bulbs, the XTZ750’s setup required a bit more customization. The LED headlights I chose didn’t fit directly into the stock mounting points, so I had to create a custom holder for them.
I designed a 3D model for a bracket that would perfectly hold the LED lights in place. Rather than using an off-the-shelf solution, I wanted something that would be durable, precise, and tailored for my bike.
A friend of mine, who has access to a CNC machine, helped me cut the bracket from 2mm thick stainless steel. This ensures strength and longevity, especially when dealing with the vibrations and rough conditions that adventure bikes like the XTZ750 are built for.
Installation Process
With the bracket ready, the installation process was relatively simple:
- Removing the Old Halogen Headlights – The stock headlights and brackets had to come off. Given the age of the bike, the original plastic connectors were brittle and crumbling.
- Wiring and Connectors – While the new LED headlights were plug-and-play, I took the opportunity to replace the old connectors with fresh, heat-resistant ones. This small step prevents electrical failures down the road.
- Mounting the LED Headlights – The new stainless steel bracket lined up perfectly, making installation a breeze. The LED units fit securely, and the new setup looked fantastic.
The Final Result
Once installed, the difference was night and day—literally. The LED headlights provide a much brighter, whiter light compared to the old halogens. With better visibility at night and improved energy efficiency, this upgrade was well worth the effort.
This project was another step in modernizing my XTZ750 Super Ténéré, making it a more capable and reliable adventure bike. If you’re considering a headlight upgrade for your motorcycle, custom brackets and LED conversions are a great way to bring old bikes into the modern era.
The LED Headlights I Used
For this upgrade, I chose Universal 5 3/4 Inch 5.75″ Led Car Motorcycle Headlight LED headlights, which provide powerful illumination while consuming less energy than traditional halogen bulbs. They feature:
✔ High-intensity white light – Increases visibility at night and in low-light conditions
✔ Lower power consumption – More efficient than halogen bulbs, reducing strain on the motorcycle’s electrical system
✔ Plug-and-play installation – No complicated wiring needed
✔ Durability – Waterproof, shock-resistant, and designed for tough riding conditions
You can get these LED headlights here. If you’re upgrading your XTZ750 or any other adventure bike, these are a fantastic option!
