Bi-Xenon Projector Install / How To - ZX6R Forum
 
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post #1 of 31 Old 01-29-2012, 06:33 AM Thread Starter
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Bi-Xenon Projector Install / How To

Hey guys,

I decided to finally stick my projectors in the bike.
I'll try and post as many pics/videos as possible so you can see exactly what I done.

This is on going so check back to see up to date progress.

First things first, get the headlight removed

Then remove all the bulbs and rubber seals:



Now you want to preheat the FAN assisted over to 150C (300F)



Now having a look at the headlight, the only parts which now hold the lens onto the headlight is these clips: (4 in total)



Now you need to find yourself a nice bit of think wood, or dense wood like birch or mahogany and stick the headlight on it to save from deforming other parts of the headlight from the heat:



Now set your timer for 3 mins:



Then Stick her in:



Now wait.. for roughly 3mins (funnily enough), then grab your mits:



Now take the lights out and place on a suitable work surface.

NOW LISTEN TO THIS PART.

Using flat wide objects like a wide screw driver etc pry the sides up ensuring that the clips are not holding onto the lens.

Now you must work SWIFT not quickly as you want to take your time with this but not so long that the glue gets cold.

A little bit of force is required but work your way round and round the lens till it starts to fall free.

Now be careful and make sure you do not get any of the adhesive on the lens projector etc etc, if you have to, when its stretches (like cheese on a pizza) just pull it off with your fingers, roll into a ball and discard.

Now hopefully you should have the first side off (for the people with separate lenses):



So now onto the other side, since you have take your time doing it, its time to stick it back in the oven again for another minute (only 1 min, as anymore is just over kill)

bring it out and same again with the other side, pry open the lens.



and thats how easy it is getting the lens off,

now you have full access to the projector and the surround to do as you please.

I will also mention now you have the lens off, cover them in cling film or as such to prevent scratches if your working on them:



So far I have done this and I've started modifying my projector to fit into the housing but this will come late, keep an eye out for updates.

Steve

Last edited by Steve; 01-29-2012 at 07:13 AM.
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post #2 of 31 Old 01-29-2012, 06:33 AM Thread Starter
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Here is a video of what is next in the process

Modifying the projector to fit the standard housing.

http://www.youtube.com/watch?v=hn65xFq_9jo&list

the video was cut abruptly at the end due to memory space running out, but I got what I needed in.

I'm going to post up more pics later in the follow up to this video.

Steve

Last edited by Steve; 01-29-2012 at 01:57 PM.
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post #3 of 31 Old 01-29-2012, 06:33 AM Thread Starter
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Ok so now you have the projectors out and your sticking in your new Bi-Xenon ones.

Mines, which are the FX-R projectors, are a little big.

At first I thought I would have to cut up the headlight a little bit to make room but after having a play with the projector in the headlight I've managed to get it in a position where is sits snug.

Now I wanted to keep the adjustment screws in use (the ones you use to change the direction of the beam from left/right or up/down).

This consisted of 3 screws to which bolt onto the standard projectors.
Since mines do not line up I decided to make a bracket to which the projector will be bolted to:



My original template was a bit thin in places, making the metal bracket a little weak but where I could I increased the size to make it more sturdy.



Now here is a look at the projectors with the brackets attached:







Make sure you have the tilt on the projectors set correctly before bolting anything down, last thing you want in one cut off line sloping left and the other sloping right.

What I did was bolt it on with 1 bolt then rotated the projector clockwise or anti-clockwise to get the cut off line flat (and I mean flat… I had a spirit level out… haha)

Once your cut off line is flat then the minor adjustments like up/down and left/right can be done with the standard screws already on the headlight.

Now this is the new projector in the headlight compared to the standard projector:





a trial fit with the lens:



Looking good so far… now the second one:



Coming together just nicely.

Now here is a quick explanation of what I've just done in a video:

http://www.youtube.com/watch?v=rLjR-3kl604

Now next I will be going into the smaller details like, covering up escaping light and painting the projector etc etc… keep posted.

Steve

Last edited by Steve; 02-10-2012 at 03:26 AM.
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post #4 of 31 Old 01-29-2012, 06:34 AM Thread Starter
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Ok first things first.

I'm going to answer a common question, Why Dont You Use The Standard Projector?

Simple... Its not good for light output.
With HID you can get a lot more light out than a standard halogen bulb so therefore the projector is made different, It spreads the light.
Unlike a halogen projector which is more concentrated due to the lower light output from a halogen bulb.



Anyways, Moving on...

I got these:

High Temperature Black Paint and Aluminium Tape



The high temp pant is for spraying the projector as there was a little too much silver showing when I trial fitted the projector so wanted it to look more subtle.



Finished:





Now the Aluminium tape is to cover up any gaps the projector lets light out of so that the only light coming out is from the front:





Now she is beginning to look the part



Just a little pic to see how she sits in the plastics:



Now I want to make sure she seals up perfectly. At the back of the projector there is a rubber seal, and it does not fit the new projector.
So I cut a strip of metal out and JB welded it to the projector to make a nice tight fit so it will be sealed off:





And here is it with the rubber on it so you can see what will be visible behind the headlight:



So now I'm just waiting for the JB weld to completely cure and be solid so I can get the projectors in for one last time and get the lens back on them for the final adjustments.

In the next thread I'll be covering the final adjustments and the resealing of the headlight and maybe if I'm luck a little video of the final shot at night

Keep tuned

Steve

Last edited by Steve; 02-14-2012 at 01:08 PM.
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post #5 of 31 Old 01-29-2012, 06:34 AM Thread Starter
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One last slot of easy viewing


*insert content here*

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post #6 of 31 Old 01-29-2012, 12:58 PM
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post #7 of 31 Old 01-29-2012, 08:38 PM
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Yes Steve!!

Looking great so far!


What projectors did you go with?
HIDs and what temp rating?


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post #8 of 31 Old 01-30-2012, 10:47 PM Thread Starter
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My set-up is as follows:

FX-R Bi-Xenon Projectors
D2S 4300K Bulbs
35W Slim Ballast

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post #9 of 31 Old 01-31-2012, 12:00 AM
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Excellent.

Do the FX-R projectors bolt right up? or do you need to do some modifications to make it fit?

just to help this be a more educated thread. What is the difference between a d2s bulb and a regular say H1 or H7 HID bulb? I know the D2S bulb is a superior bulb just not sure in what way

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post #10 of 31 Old 01-31-2012, 06:13 AM Thread Starter
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FX-R projectors don't fit perfectly but I'm going to do a bit of modifying to make it fit, keep an eye on the thread and you'll see the progress.

If you want to know about the bulbs see my other thread giving all the information you need.

http://zx6r.com/zx6r/22111-everythin...hid-xenon.html

Steve

Last edited by Steve; 01-31-2012 at 06:15 AM.
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post #11 of 31 Old 01-31-2012, 07:55 AM
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Good job! I'll be keeping an eye on the progress!

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post #12 of 31 Old 02-08-2012, 10:46 AM Thread Starter
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going to get a video on the go soon to give you an update on the progress.

but in the mean time here is a couple of teaser pics:









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post #13 of 31 Old 02-08-2012, 10:57 AM
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what's wrong with the stock projectors? just curious

and I can't wait to see it with 4300k I don't like the gay blue hid's people put on
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post #14 of 31 Old 02-08-2012, 11:09 AM
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Stock projectors are not HID projectors. I'm sure you and others have noticed how if you put an HID kit in stock headlights, the light output near the bike isn't as smooth. It looks like a ring of light on the ground in front of the bike. This is because the stock projectors are made for halogen bulbs and directs the beam differently than a true HID projector would.

The OP is also using bi-xenon projectors which, I'm assuming, means that both projectors would be on for low beam and also high beam. Bi-xenon projectors have an internal solenoid that activates a mechanism when high beams are triggered. This causes the cutoff of the light to be raised which mimics high beams.
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post #15 of 31 Old 02-08-2012, 11:11 AM Thread Starter
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The standard projectors in the headlights are for Halogens only not HIDs.

so i'm changing mines to Xenon projectors, not only that they are bi-xenon so both will be on and both can do high beam.

My pictures only show 1 as i've only got one temporary fitted in.

Also those are 4300K I have in that projector.

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