5th Gen VFR 800 HID Projector Retrofit

[silverbullet132]

http://www.theretrofitsource.com/complete-retrofit-kits/bi-xenon-mini-stage-3-kit-d2s.html


First, remove the headlight and front cowl from the bike. Remove the 4 screws holding the headlight assembly to the cowl.


Get 2 or 3 flat blade screwdrivers, and preheat your oven to 235f. Once heated, put the headlight assembly on either wood or cardboard, and put it in the oven for 10min. Once the time is up, remove the assembly with oven mitts. Pry between the edge where the front pushes on (sorry forgot to grab a pic) and pry the lens off.


This is what you will have (mine is taped off for painting)

If you wish to paint yours, I recommend Krylon Fusion

Shave/cut the 2 lower tabs of the locator ring off, just as if it was a normal bulb going in

This is where it gets tricky. You have to shave/cut about 2mm from this, as the lock nut for the projector will have no room to grip otherwise. (remove the brass bracket on the left)

Then drill a hole to run your solenoid wire through, close to the hole the projector went through. After that, install the projectors.

Since I used huge shrouds and square projectors I had to do a bit more cutting

Shrouds painted

Get some Butyl glue, stretch it out a bit, and push it into the space between the lens and other half of the headlight. When done all of the above, place the lens on top of the lower half, lining it up the best you can


Put it back in the oven at 235f for 10min, and use pliers to push the 2 halves together. Let it cool, mount up your ballasts (side of the headlight housing works well) then reinstall to the front cowl, run the wiring and your done!

 

[rye]

Nice work, looks great! How's the beam pattern look?

 

[silverbullet132]

Nice work, looks great! How's the beam pattern look?

Really nice and crisp. Does not even look like I have to aim them much if at all, since I did not take the reflector bowls out of the headlight.

 

[rzresurection]

Great job. That looks awesome

 

[silverbullet132]

Great job. That looks awesome

Thanks, after testing them at night HOLY CRAP! They throw the light so far and the cutoff line is really sharp. Love it, well worth the effort.

 

[rzresurection]

How come you painted the reflectors? I know they aren't really needed now. Just to make it look black inside the headlight cavity?

 

[rzresurection]

I'd like to do this to my bike, but I have the old glass headlight style. I'm not sure how to do this.

 

[silverbullet132]

How come you painted the reflectors? I know they aren't really needed now. Just to make it look black inside the headlight cavity?

Yeah, when the bike is off and when it is on it looks much better.

Could be done to your bike but you need to have a clear front lens, and if it is sealed beam that makes it a bit harder but it is still possible. Pm me if you need more info/help

 

[rzresurection]

I have a clear glass lens. It's not a sealed beam. It uses a replaceable H4 bulb. I'm not ready at this point to do this conversion, but I am curious as to how it would be done.