CRF300L HeadLite, discrete navigation tower

The new Ver 2 can be found here:

Intro

This is a DIY-project for building a replacement headlight for the European (2021-2024) version of the CRF300L. I suppose the US version will also fit because the headlight looks the same. It is not compatible with the new EU version (2025 – ) nor with the Asian/Australian version of the CRF.

It makes it possible to attach an Asian/Australian headlight visor and also functions as a lite navigation tower.

Instead of the original Asian LED unit, it uses street-legal Hella M60 low beam and high beam lights. The beam of these lights can be adjusted using printable spacers (+/- 0 to 5 degrees).

On top of the “HeadLite” there is room for mounting a GPS, phone, CarPlay-unit or small tablet.

The weight of the entire HeadLite without the Navigation Mount is 1560 g, which is 730 g heavier than the stock headlight.

If you own or have access to a 3D-printer, have some soldering skills, you can build this entire HeadLite yourself.

Questions? You can post them on reddit or advrider.com

If you want, you can buy me a coffee.

Printing

Filament used: PETG

Print Settings

• Layer height: 0.2mm

• Perimeters: min. 6 (important for strength)

• Fill density: 15%

• Fill pattern: Gyroid (important for strength)

• Supports: Support on build plate only

Base Frame

The Base Frame is the part which is bolted directly to the motorcycle.

Ver 1.2 – Tilted 5° upwards and made the attachment parts stronger (again). This will require extra 5mm washer/spacer for the high beam.

• Ver 1.0 – Initial version

• Ver 1.1 – Tilted 5° upwards and made the attachment parts stronger. This will require extra 5mm washer/spacer for the high beam.

• Ver 1.2 – Tilted 5° upwards and made the attachment parts stronger (again). This will require extra 5mm washer/spacer for the high beam. This version replaces ver 1.1 because the upper attachment points did not survive an offroad trip to Wales. Luckily it was an easy fix using zip ties.

The original headlight can be detached after removing the 4 bolt.
Remove the 3 washers and 4 rubber grommets from the original headlight unit.

Following hardware will be reused:

Attach the grommets and washers to the 3D-printed Base Frame.
You can use a flat screwdriver to push the grommets through the hole.

The 4th washer is attached directly to the bike. It is the upper attachment point, situated on the throttle side of the bike.  
You need to lift the grommet over it. When removing the headlight, this comes last. When installing, this comes first.

Headlight Frame

Ver 1.0 Initial version

The Headlight Frame requires 18 x M6 threaded inserts: 8 for the Spacers, 6 for the Base Frame attachment and 4 for the top Navigation Mount.

When using the Base Frame Ver 1.1 you will need 4 extra washers (M6 5mm spacers). These can also be printed. The washers need to sit between the high beam “Hella M60 Spacer” and the “Headlight Frame”. This will make the high beam light sit 5 mm further to the front, away from the dashboard.

For fixing the Headlight Frame to the Base Frame you will need 6 bolts M6 x 20 mm countersunk.

Visor Frame

Ver 1.0

Initial version

Ver 1.1

Added “tubes” around the holes to prevent light bleeding.

Print Settings:

• Layer height: 0.2mm

• Perimeters: min. 2

• Fill density: 15%

• Fill pattern: Gyroid (important for strength)

• Supports: Support on build plate only

You will need to reuse the 4 screws from your European Visor.

Ignore the cut-out of the visor in the picture, these are the remains of a previous project. 

Hella M60 LED Spacers and Wiring

Various Navigation Mounts

Parts required

	1 x CRF300L Visor 61300-K1T-J50ZA https://bikerzbits.com/visor-set-fr-wl-type1-61300-k1t-j50za.html Since the 2025 version, the European model also uses the Asian visor. This means that the part will probably be available at European dealers.
	Threaded Inserts M6