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I well remember in 1975 when I first used the headlight on my newly purchased 239cc Mark 3. I simply couldn’t believe how poor it was. In fact, I had to put my hand in front of it to ascertain if it was switched on! After various incidents, I replaced the Aprila headlight and nasty Italian dip switch with a Lucas 7” unit and a Suziki handle bar switch. The improvement was dramatic. Now some 40 years late I am restoring the same bike. I have a rusty Aprila headlight (original fitment) and a rusty Lucas headlight. What do I do? I could get the Aprila rechromed; get a NOS Aprila replacement or buy another 7” Lucas headlight. Purists might argue for rechroming the original but I am convinced that it suffered from poor design; great at lighting up the hedgerows and pavement but bl***y useless as a working headlight on dark country lanes. Is there some alternative which will preserve the “Aprila” headlight appearance but provide modern standards of lighting? The Micky Mouse Aprila switchgear, I’m afraid, is not going to get a second chance

You could try LED headlight as a cheap fix

I think that the answer lies in whether you are doing a faithful restoration, or whether you want to ride the bike. I think that the Lucas light looks better, and if it means more safety, then that is most important.

Converting the system to 12 Volt will also improve the headlight's brightness.

cheers Hans

IF it was mine, I would:

- install the original headlamp and switches, main and dip.
- use a relay to prevent high currents from going through the switches.
- try to find a different reflector/insert, one that fits and focuses better.
- fit a quality headlight bulb with highest wattage that the charging system can handle.

Aye Dodge,

Back in '77 or thereabouts the headlight on my '74 450 MKIII was already badly corroded from the inside out and the electrical contents failing rapidly and frequently. The switches were also very nasty, lots of verdigris of the terminals and the attached wiring. It's known as "patina" these days! As the bike was my only means of transport I removed the lot, purchased a fibreglass replica headlamp shell and headlamp for a Honda 400/4, fitted a 45w/45w 12v bulb, along with converting the electrics to a 12v system using a 'Radio Spares' bridge rectifier, and Lucas zener diode fitted in the lower fork yoke and was at last able to travel the back roads of Mona's Isle, Cumbria and the M6 to Hertfordshire, with some reliability and ability to 'see' at night. I still have the 400/4 headlamp fitted and you can view it here: Honda_400/4_replica_headlamp_on_'74_450_MKIII

In my opinion, if you wish to keep it 'original' no problem, but it'll cost a fortune and be impractical to use at dusk or later. If you want to use the bike and that includes the odd evening canter in the gloaming, fit the new Lucas headlight shell along with a 12v LED headlamp unit, relays, even though LED do not have large current requirements and a solid state rectifier, of which there are many options.

Keep the 6v horn as the note is VERY penetrating when fed 12v! And if it burns out they are not that expensive.

Rechroming a pitted headlamp shell is expensive. I asked for a headlamp rim to be plated and the bill was £60! A nice job, but I could have bought a new headlamp for that and felt a right mug! Removing the chrome is the easy bit and is achieved by reversing the anode and cathode of the plating process. The polishing out of all the pitting to achieve a smooth finish is a time consuming pain and then you still require the final chemical etch before the copper, then nickel, then chrome plating with rinsing in between and final polishing. Labour time will be at least £45 per hour and if it takes a conservative 4 hours to do the job......need I say more?

Maybe try a powdercoat chrome finish and hope the sand blast leaves you with a shell to coat!

Enjoy the bike whatever you choose.

Good health, Bill

Safety first.
If I was to ride after dark my preference would be illumination, not originality.....
If you are not using the Aprilia switch then who cares if the headlight is also not original. And the Lucas 7" probably looks better than the original anyway......
12v if possible. And as big a wattage as your alternator will allow.
I only ride at night if there is absolutely no alternative. Too many roos around here.....

Cheers
Dan

My 239Mk3 is going back together and I chose to go down the 7” Lucas route for a headlight. Made in India, the chrome looks pretty sound - £75 inc VAT and came with an integrated ammeter. Now, my electrical knowledge is a bit basic and I could do with some expert advice about incorporating the ammeter. My schoolboy physics tells me that I need to wire it in parallel but where?

Aye Dodge,

Does this diagram link below help?

Wikidoc_ammeter_wiring diagram

I would suggest that reading the associated text at the link would be helpful.

Electrickery is not my forte! Hans (ducwiz) and others are more attuned to this than me.

Good health, Bill