Super Tenere XT1200Z Large Headlight Cover for LEDs

thingiverse

Update: After 2 weeks of use, the heat from the heatsink and driver was too much and the PETG deformed too much. Using a temperature controlled heat gun, I've reshaped back into the original shape and now testing with a lower powered LED module with integrated driver (no external driver box). Fits LED lights which have a separate driver module. It will fit with just enough, maybe a few millimetres of clearance to the forks with the steering at full lock. Tested on 2014 model Super Tenere. Print in 3 pieces and glue together. Orientate model so minimal supports are needed. The rear cover can be laser cut using the DXF file, this is a lot faster if you have a laser cutter. I used 2mm acrylic for the rear cover. Re use your old O-ring from the OEM headlight cover. Test fit the adapter and once in the locked position, place the casing against it to test fit with the steering at full lock. Position to give maximum clearance to the forks and mark with a marker. Glue all pieces together. I used polyurethane glue with a few spots of CA glue in some areas to hold together instead of clamping. PU glue will otherwise expand when drying and separate your pieces if they are not clamped. Printed in PETG, glued, dried, sanded, primed and painted black. Materials and glue seem to handle the heat adequately so far after a few rides. The outside of the printed housing gets warm to touch. It fits my Chinese [Bevinsee 60W V45](https://www.bevinsee.com/products/bevinsee-v45-h7-led-headlight-bulbs) LED H7 bulbs. But it still a tight fit and takes some fiddling to get the driver module positioned inside the housing right before the housing can be push fit into place. Please take extra care at headlight aim when using super bright LEDs to avoid blinding oncoming motorists, I aimed mine lower than normal, and it is still good visibility at night time. Other LED options and reference: - [Cyclops LED](https://www.cyclopsadventuresports.com/-led-headlight-conversion-kit-yamaha-super-tenere-xt1200z.html) - [Large headlight cover](https://www.thingiverse.com/thing:2413145) by BikeLord