I've always been able to secure a 5 3/4" H4 reflector/lens into the stock chrome ring on the older and newer models. This includes all the 175/250/360/400's.

New models had spring clips... you can use the Yamaha ones off a later model, the ones from MikesXS, or Yamahamadingdong came up with a trick using binder clips. See thread here: yamaha-enduros.com/index.php/forums/gene...lacement-trick#98822

Sure, on the earlier models you lose the silly "adjustment" that you don't need anyway... but it works fine. Just use the clips to hold the new H4 into the rim instead of the brackets.

P.S. Gluing a new bulb into an old reflector is just not a good idea in my experience... the original bulb filaments are precisely located in the reflector... very precisely located... to focus and direct the light beam. Move the filament slightly and the pattern is garbage. Or will blind other drivers. (High and low beam is not as much about the wattage as where the filament is placed within the reflector.) en.wikipedia.org/wiki/Parabolic_reflecto...abolic_reflector.svg

Ha ha, I knew there was some reason I was holding on to this! Just so happens one clip was missing from my assembly, so now I can bend this into the necessary shape.

I finally finished fitting a new headlamp to my DT360A and I am happy with the results. I used a Hella Vision Plus Conversion Headlight #002850001 I got from Summit Racing for $29. It accepts inexpensive H4 bulbs so I can use either the 12 or 6 volt versions of the bulb, and it is easily replaceable. And the H4 bulb uses the same 3 prong socket as the original headlamp so no wiring modifications are necessary from stock, it plugs right in. Even the stock headlamp bulb retainer spring clips work just like on the original lamp.

A couple of not too difficult modifications were necessary to make this work. The glass on the Hella light projects out through the chrome ring unlike the original sealed beam. That glass is about 1mm too large for the headlight ring, so I had to carefully grind away that much metal from the ring with a Dremel and stone bit. That’s not very much so it didn’t take long. Now the glass fits through the ring and I like the way it sticks out when viewed from the side. There are also two little raised metal tabs on the Hella behind the glass that I had to carefully remove to make the light orient properly in the ring. Again, I used the Dremel and a thin flat stone sawing bit to cut them off. Other than that it just takes a little fiddling to seat the headlamp and work the rubber cover onto the back of the lamp with the bulb in place. All told this was about an hour’s work, not bad at all. And the new lamp has a nice retro look that goes with the bike and does not look out of place.

Nice work!
I agree, that Bug Eyed look with headlight popping out a little bit looks cool.

I used Hella’s on two of my bikes, they were 7” but a huge upgrade from stock.
I think I may have got them from Summit also, all I know is I got a “hella deal”.

I ordered one from Summit as well based on your great review! Does Summit ship fairly quickly? They don't seem to be more than 3 hours from me.

I got my '74 cranked tonight and when a friend of mine revved it up, the H4 bulb blew. Any way to keep that from happening again?

Read post #4 of this thread.

I just got 2 5-3/4 inch 6 volt LED headlights from Octane Lighting and they fit beautifully and are insanely bright compared to stock. There is a small transformer that fits inside the headlight bucket but initial indication are they are going to be good. I have been using LED for 5 years and they are standing up well and seem very durable but you need a regulator or you will fry the transformer.
Doug

Ordered replacement for my '74
DT 360 from NAPA $31.00, NAPA part #4020 LMP