PK125 XL disc brake and LED headlight conversion
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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 12:49 pm quote
I decided that it was time for a few upgrades for my Ď85 PK125XL. The engine is still all stock (for now), but I wanted to improve the front brake as well as the headlight.

Weíll start out with the front disc...

Bolting a Grimeca disc on a 20mm fork is fairly straightforward, so I wonít be going into any details about that part of the project. But bolting a hydraulic brake master cylinder to a non-disc headset isnít as simple.

Hereís a pic of most of the parts Iíll be using. You can also see in the pic where the perch for the front brake lever has been removed.

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Last edited by whodatschrome on Sat Sep 29, 2018 10:29 am; edited 1 time in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 12:57 pm quote
I used a piece of 3/8Ē aluminum angle for the perch bracket.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 1:01 pm quote
I drilled and tapped the holes for the master cylinder before I started welding.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 1:04 pm quote
After a few passes with the spool gun.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 1:07 pm quote
And after a few passes with the grinder, itís looking a bit better. And if you look really close, you can see the Time-serts that I installed in that bracket.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 1:10 pm quote
And a side view.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 1:15 pm quote
I also removed the front fork for a few reasons...
#1, I wanted to grease the upper and lower steering column bearings. The upper ones were dry and rusty.
#2, I wanted to paint the front fork.
#3, I installed a different front fender that I already had (that wasn't dented).

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Last edited by whodatschrome on Tue Sep 04, 2018 10:26 pm; edited 2 times in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 1:23 pm quote
A picture of the fork after it was painted.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 4:39 pm quote
I wired in a front brake light switch since the PK didnít ever have one.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 4:42 pm quote
I had to notch out the headset cover for the brake line to fit.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 4:47 pm quote
Now on to the LED headlight that will be installed on a non-battery 12VAC system. Since LEDs don't like AC power, i'll have to somehow get DC power to the headlight. Normally on any of the vintage bikes that have a battery (P/PX/LML Stella), floating the ground on the stator then adding a DC regulator is how it's done to get DC power to the headlight. A different route needs to be taken when there is no battery to wire up the LED to...

Here are some of the parts that I gathered up. All of the plastic was found at Tap Plastics. I think I paid about $10 for all of the plastic that I bought.

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Last edited by whodatschrome on Sat Sep 29, 2018 10:31 am; edited 2 times in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 4:51 pm quote
I spend quite a few hours figuring out what diameter and thickness I wanted the plastic to be. I made a few different sizes and colors for experimenting.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 4:56 pm quote
I used the router to countersink the bezel of the LED into the HDPE black plastic...which in turn, that bezel will get ďsandwichedĒ between the outer white colored piece of acrylic plastic

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 4:59 pm quote
When mounted together, it looks just like the light in this picture. Itís a fairly thin profile.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:03 pm quote
I got some brass threaded wood inserts. They will be used as a pivot for the light assembly. I drilled a hole in the HDPE, and screwed them right in.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:04 pm quote
What it looks like threaded in.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:09 pm quote
After I very carefully measured exactly where I need that threaded insert placed, I screwed in a stainless steel Allen head cap screw. That cap screw will act as the pivot for the light assembly.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:16 pm quote
Now onto the wiring...
Very sharp viewers will notice that the headlight wires are coming from the left side of the headset. Thatís because here in America, we have our headlight switch on the left handlebar (turn signals on the right side). I wanted my PK to be like my other scooters, so I swapped sides with my switches.

Since I wonít have a dimming capability with my LED, I will only be using the purple highbeam wire and a ground wire from the switch. I removed the brown low beam wire, along with the white pilot light wire.

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Last edited by whodatschrome on Tue Sep 04, 2018 10:19 pm; edited 2 times in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:23 pm quote
The wires I have left coming from the light switch are a purple and black. You can also see that I have drilled about a 3/16Ē diameter hole in the headset. That hole is there to bolt in the AC to DC converter box.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:26 pm quote
A picture of the box bolted in, and wired to the LED light.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:30 pm quote
And plenty of room for the converter box and the headlight.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:34 pm quote
Hereís what it looks like installed. I still need to make a third attachment point for the headlight assembly. That will need to be done at night, so that I can properly aim the light.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:40 pm quote
Fast forward 24hrs later...

I figured out exactly where I needed the third mounting point. I made a little L bracket that will be used, as well a two more of those brass threaded wood inserts.

I used a drill bit stop so that I wouldnít accidentally drill all the way through the plastic.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:42 pm quote
Hereís a pic of the L bracket once it was modified and painted.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:45 pm quote
And a few more pics of the scooter with it all buttoned up.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:48 pm quote
A front view, right before the unveiling of the new headlight.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 5:54 pm quote
...and the final product.

The LED definitely changes the whole looks of the scooter. I would be nice to have a light that is more ďclassicĒ looking, but having a bright headlight for me at night is of the most importance for me. There are LOTS of deer and a large herd of elk where I live. I donít want to hit another one.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Aug 29, 2018 6:03 pm quote
I canít think of any downsides for me installing the LED in my PK. I used a Baja Designs S2 LED that has a ďwide corneringĒ lens. It has a little bit better of a light cutoff, compared to some of their other lenses. The LED does flicker some at a very low idle. If the throttle is opened to about a 1/16 of a twist, the flicker goes away. I spoke to Baja Designs about this, and they said thatís just how the converter box operates. Itís not because there isnít enough power from my stator, itís just how the box is designed. They assured me that it wonít cause any damage to the LED.

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Member
Lx 50 4t
Joined: 08 Jul 2018
Posts: 39
Location: New york
Thu Aug 30, 2018 6:49 pm quote
They are right. I also have an LED headlight and it blinks a little on idle but if you adjust the idle it does get better. I've never had issues with my leds
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 6499
Location: Victoria, Australia
Tue Sep 04, 2018 2:47 am quote
Nice work as always WDC. How do you find the spool gun to work with? I bought one but haven't gotten around to hooking it up as yet.
Molto Verboso
Joined: 26 Oct 2015
Posts: 1132

Wed Sep 05, 2018 9:26 pm quote
Ginch wrote:
Nice work as always WDC. How do you find the spool gun to work with? I bought one but haven't gotten around to hooking it up as yet.
I have a 260amp ESAB MIG welder. About a year after I bought it I purchased a ESAB spool gun for it. Itís just an OK gun, itís nothing too fancy. I had a difficult time figuring out what to adjust the controls to. After a friend came over and gave me a baseline to start with, I then started to lay down some semi-decent beads.
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