DIY Dirt Bike, Dual Sport & ATV Headlight Guard on 4Strokes.com

4Strokes.com Technical: DIY Dirt Bike, Dual Sport & ATV Headlight Guard

This is an inexpensive and very effective headlight protector, originally built for a Honda XR400R (non US model) by Jan van Wijk. This headlight protector can easily be adapted for other makes and models of dirt bikes as well.

Bolt-On Dirt Bike Headlight Protector
Homemade Dirt Bike Headlight GuardThe following materials are needed for construction:

Two small pieces of stainless steel about 80mm x 20mm x 1.5mm.
Two stainless steel M4 screw.
Two stainless steel M4 washers.
A piece of Plexiglas about 170mm x 100mm x 4mm, or slightly larger than your headlight.

The headlight protector can be constructed in about 45 minutes using simple hand tools:

Bend over 10mm of both stainless steel pieces.
Drill 8mm holes in the long end of the stainless steel pieces.
Drill a 3.2 mm hole in the 10m short end of the stainless steel pieces.
Tap M4 threads in both 3.2 mm holes.
Take off the headlight protector.
Install both stainless steel pieces on the headlight bolts.
Re-install the headlight protector.
Round off the the Plexiglas corners.
Drill two 4 mm holes in the Plexiglas and fit it on the bike.

Credits: Jan van Wijk built his entire headlight protector for about $4 USD.

Velcro-On Dirt Bike Headlight Protector This is another type of dirt bike headlight protector/guard using hook-and-loop fastener. This method allows for easy removal of the headlight guard for cleaning of the headlight and guard itself.

Headlight Guard: Virtually any thickness of Plexiglas will work. However, thinner material around an 1/8" or 3mm would probably be best. Simply just cut it to the shape of your headlight.

Attachment: We would suggest using a strong type of hook-and-loop fastener as the inexpensive light-duty white stuff (shown to the left) does not last long with constant exposure to the elements. You can find the heavy duty hook-and-loop fastener at any good hardware store and most automotive type stores. With the hook-and-loop fastener mated together, cut four pieces and stick them to the headlight. Remove the adhesive protection from the back of the hook-and-loop fastener that is now attached to the headlight and attach the guard squarely over the headlight.

Credits: This particular headlight guard is by Mr. Ron Jackson of Arizona

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Molding Plexiglas to a Headlight

If you take the Plexiglas and place it in the oven at about 300 degrees for about 2 minutes it becomes soft and pliable.

Put wax paper over the headlight.
Rest the precut Plexiglas on tinfoil in the oven and wait until it starts to look glassy
Wearing gloves, quickly place the Plexiglas on top of the headlight and push it over the edge to form it around the lens.
I cut the Plexiglas oversize and trimmed it after it was molded.

Cautions: Plexiglas stinks when it's heated and will most likely catch fire if left in the oven for a long period of time.

Credits: Tip provided by Tom Murphy - YZ426F woods in NY (2-26-05)

If you have another method of protecting a dirt bike, dual sport or ATV headlight and would like to share it with others, please send it in care of the webmaster to the email listed on our Contact page. Thanks!

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