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<DIY> Projector Lens Retrofitting - Not For The Faint Hearted


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During the course of my retrofitting, I burned two fuse and literally burned my hand. But it all went well, and I am damnnnnnn happy!

 

Total hours spent: 5 hours ( can be faster, if I never burn the fuse)

 

Items bought:

(a) projector,

(b) Projector shroud,

© H1, 4300k, 35watts, xenon bulb,

(d) 35 watts ballast,

(e) H4 male connector,

(f) wires (capable of handling high voltage), &

(g) Hella 20A relay.

 

To be continued....... (upload photo first)

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0508.jpg

 

Take out the head lamp assembly from my bike.... its a GSR400 =D

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0509.jpg

 

Using heat gun.. pointing it to the direction of the sides... Its all about heat control. Too long and you will burn your casing, or worst, cause bubbles on your glass....

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0510.jpg

 

Slowly pry open the housing.....

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0513.jpg

Tada!! Finished opening...

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0515.jpg

 

Adding the silicone gel provided...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0517.jpg

 

H4 ring provided as well...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0518.jpg

 

Put the ring around the hole, and screw it in...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0519.jpg

 

Step 2 finished!

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0520.jpg

 

Photo by the side

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0523.jpg

 

next step is to put in the retaining clip...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0524.jpg

 

And the bulb..... prep it...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0525.jpg

 

Slowly inside the bulb into the hole and clip it.

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0526.jpg

 

Step 3 done!!!

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0527.jpg

 

Get it ready to check whether it is straight and not senget.

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0529.jpg

 

low beam... NICELY DONE!! its level!

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0530.jpg

 

Testing high beam... yeeehaw!!

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0532.jpg

 

Time to fit back the front casing! Put in high temperature silicone gel...

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0533.jpg

 

Take out the high beam side..

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0535.jpg

 

Attach it to the positive side of the high beam. (red wire coming out from the projector)

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0536.jpg

 

Place it back in..

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0537.jpg

 

Next is to take out the negative side...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0538.jpg

 

Place it back in... Finished product.

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0540.jpg

 

Testing out the hella relay... and also the lamp =D

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0543.jpg

 

Open up the bike... (this is the lazy part zzzz)

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0544.jpg

 

Connect the positive and negative terminal to a long wire (to power up the ballast)

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0545.jpg

 

 

Due to the testing of relay, i burned two fuse! haha!!

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0546.jpg

 

Finished up the wiring, and fix it back.. woohoo!! can't wait for try it out....

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http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0547.jpg

 

Hmm... looks hazy inside there. LOL

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0550.jpg

 

Test out low beam...

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0551.jpg

 

And high beam.... Sibei sweee la....

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0554.jpg

 

Lets test out on the road (low beam)... Looking gooood.. no glare at all..

 

http://i887.photobucket.com/albums/ac71/asmiforex/Retrofit/DSC_0555.jpg

 

and high beam.... GO AWAY! I'M PASSING THROUGH!

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There is have it.. my write-up on my projector lens retrofitting.

 

Previously I fixed HID before, however it was too glaring. As complained by my friends, thus I search out for the best projector, and the best way for retrofitting.

 

Next project:

Switch for leveling the HID up and down =D

 

I will start a MO soon for whoever wanna retrofit it to their bike. Now its time to me.. to go riding!

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There is have it.. my write-up on my projector lens retrofitting.

 

Previously I fixed HID before, however it was too glaring. As complained by my friends, thus I search out for the best projector, and the best way for retrofitting.

 

Next project:

Switch for leveling the HID up and down =D

 

I will start a MO soon for whoever wanna retrofit it to their bike. Now its time to me.. to go riding!

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Interesting. It doesnt look like the projector assembly doesnt use the stock reflectors as its protruded. Not like it needs it, looking at the generous light throw.

 

I might do something like this with a double headlight assembly. Install one projector, and close it with a painted headlight protector. To avoid trouble with the mata.

 

How is the electrical usage compared to normal h4 bulbs?

Bajaj Pulsar 180 - UG3 (2007 - )

Suzuki GSXR-400 (2008 - 2009)

Piaggio Vespa GT 200L (2009 - 2011)

Yamaha YBX 125 (2010 - )

Yamaha FZ S1 '05 (2011 - )

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Electrical usage huh? I don't even measure. But the source of the current is directly from my battery, as I do not want to burn my H4 harness due to the high voltage requirement.

 

As far as I know, for HID, the initial starting requires alot of voltage after which, it will stabilize. :)

 

Koxie: CCFL ring ah.. I wanna avoid Mah-tah LE! LOL. I even used 4300k bulb..

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I am opening up the casing again as I want to level my headlights up and down with a click of a switch. I think it can be done..

 

Heading to Sim Lim Tower (my source of electrical components) took look for a worm gear! =D

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  • 1 month later...
  • 4 weeks later...

where did u get from?

25 Nov 2003 - 24 Nov 2004 (FS6087P) (NSR SP)

24 Nov 2004 - 28 Feb 2006 (FJ7457X & FJ*5**) (Hurricane & Vespa PX200)

01 Mar 2006 - 04 Jul 2006 (FS9367L, FJ7457X & FJ*5**)(CBR 919 RRW, Hurricane &Vespa PX200)

04 Jul 2006 - 13 Jun 2011 (FV8507R & FJ*5**)(Suzuki K2 & Vespa PX200)

13 Jun 2011 - Till Now (X1)

15 Jan 2013 - 10 Sept 2015 (FBG9588B)(GTR1400 2013)

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