Stealth - 2002 Honda Dio

Thread Starter #16


Honoured Member
Sep 11, 2009
January 2022 - H4 Conversion

Water seeps inside the assembly during rains, resulting in a blown bulb. Yet to find the leak point despite multiple leak tests.

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H4 bulb fits without much drama. Old BA20D bulb didn't have/need a retaining clip, so need some jugaad to fit the H4.

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Bought Osram Cool Blue Mega HS1 35/35 - ₹ 220.00

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Agni Ceramic Holder - ₹ 98.00

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Old headlight removed from FZ.

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Had retainer clip and rubber dust cap.

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Installed them and were perfect fit on Dio's headlight assembly.

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Dust cover also made for each other. Cut out the old connector and mated with the H4 holder.

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Plug-n-play harness.

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Cloth tape.

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One of the clips holding the light was missing.

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The clip.

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Bought two of them right away, ₹ 5.00 each.

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Cleaned up all the debris and wiped cleaned the reflector of any dirt. Lot of spotting and fading, might replace the assembly if available.

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Beam adjustment bolt under the headlight. Loosening it allows forward/backward movement of the assembly.

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Highest position.

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Lowest position.

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Corrected position.

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4300k temperature. Output is similar to old halogen bulb. Might upgrade to LEDs sometime in the future.

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Thread Starter #17


Honoured Member
Sep 11, 2009
January-February 2022 - Updates

Where it was parked for years.

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Found the Denso pair in my horn bin, removed from the Skids.

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Fiddled with the screw and back to life.

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Last horn relay from my bin, ran out.

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Quick DIY fuse holder. First time on a micro fuse.

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Plug and play horn wiring kit.

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Installed Windtones in a couple of Dios in their golden era, which was claimed to be impossible by all installers those days. There was just millimetre clearance from the body with precise bending of the clamp. These horns were smaller and flatter, so finding space wasn't hard. Would switch to Yamaha Fazer pair soon depending on availability.

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Shield mounting came off, so took it off.

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Made one more spare key. Lost the previous duplicate and spare. Just ₹80.

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