Aux light project for Honda 250 Rally


This is going to be a long winded post so bear with me. As for aux lights, the easiest solution would be to go with something like the Denali mounts and mount separate lights to the fork tubes.

I wanted something different for 3 reasons.

  1. I wanted the light(s) to be as crash proof as possible, meaning that I wanted to place them on the center of the bike.
  2. I wanted lights that would NOT turn with the steering
  3. I wanted to tinker…

Whether all this makes sense is another matter entirely.

The mounts

After some head scratching, I found that there is a cross tube below/behind the light that would allow me to insert a threaded rod through providing a relatively solid mounting point.

The idea was to construct 2 steel bars that would mount on the rod and rest on top of the fairing mounting tab. The mounting hole is drilled so, that the mounts would set on a slight downward angle to match the top line of the fender and not block the actual driving lights.

Ghetto electrical tape bushing on the threaded rod
Rubber grommet placed on the fairing mounting point

The light seems to fit very securely in place, but for “hard enduro” purposes it may require a few zip ties to keep it from moving upwards. Remains to be seen if it becomes an issue.

As it sits now, the light should be as crash proof as it can be. Crashing on either side should not affect the light.

The light

Once I had the mounting figured out, I knew what kind of light I needed. For this purpose, an 8 inch wide single stack LED light was ideal. Mine is not-so-high-quality one from Wish, as I wasn’t sure if this setup would work. In retrospect I would maybe go with something a little better, like this


ยป Rough Country – 70718BL – 8-inch Black Series CREE LED Single Row Light Bar for Anywhere You Can Mount It


Lots of options out there. The key is to have mounting holes in the ends.

The switch

To give the project some extra challenge, I wanted the switch on the dash, not on the bars. Placing the switch on the bars is a no brainer, but I wanted to figure out if there was a way to mount it cleanly on the dash.

I discarded the switch that I had an ordered a better looking one. This:


ยป Feiteplus 7/8″ Motorcycle Handlebar Mount ON-OFF Switch DC 12V For Motorbike Fog Lamp Head Light Electrical System

I found another tube under the dash, that again allowed me to insert a threaded rod for mounting.

I wrapped some electrical tape on the rod for a rattle free experience and snug fit.

The mounting rod. Notice the bushings made out of electrical tape.
Added rubber grommets on both ends for a friction

On the rod I placed an aluminum spacer (unfortunately not black) that would allow the clamp of the switch to be attached securely.

Aluminum spacer on the end

The other end of the rod is capped by a nut and there is no room for anything else as the ABS switch gets in the way. (removed in the pic for installation)

The other end

The location of the switch allows the wires to run very cleanly and not bind in any situation, as nothing moves with the steering.


The view is rather clean.

I’m pleased with myself, that I could figure out a working solution, but I will tinker with it some more. My plan is to have the standard high beam switch control both the high beams and LED bar and have the newly installed dash switch in between. This would allow me to have the led bar either to switch on when high beams are turned on or stay off at all times.


The light could be a tiny bit wider for optimal fit


The ideal width of the light bar would be 210mm. I had to use some spacers on mine.
The front looks even goofier now


Enough room to adjust the beam
Honda CRF 250 Rally LED bar aux light
Honda CRF 250 Rally LED bar aux light
mounting point (nyloc nuts not yet installed)
The mounting bars rest on the fairing mounting point



12 Comments Add yours

  1. Andrew King says:

    Very nice. Well done for taking a new approach ๐Ÿ‘๐Ÿป

    Liked by 1 person

  2. Barry D Stamper says:

    Will this work for the CRF250L non-Rally?


    1. 250rally says:

      Not directly. The front is different, so the mounts I used will not work.


  3. Dylan Field says:

    How’s your experience been now you’ve had it for a while? I want to do the same for my RTW setup and this looks like the best position to avoid the light array getting damaged from falls.


    1. 250rally says:

      Don’t have the bike anymore, but the current owner has not reported any issues.


  4. Sigit Adinegoro says:

    Sold your bike?


  5. sadinegoro says:

    What? You sold the bike?


  6. su says:

    Sold your bike


  7. Dylan Field says:

    This is an excellent idea and I ended up grabbing a mount from SRC Moto for a Lightforce 6″ bar. It won’t get damaged in a crash and over doubles the output of the standard lights. I did this for my melb > London 50,000km rally build. Thanks for making this, great job ๐Ÿ‘


  8. Trebuh says:

    Very nice. Well done for taking a new approach. ๐Ÿ™‚


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