Dual HID Info thread - ZX6R Forum
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post #1 of 31 Old 01-17-2012, 12:31 PM Thread Starter
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Dual HID Info thread

Hey guys,
This is a BASIC information based thread for changing your standard headlights into dual bi-xenon.

First things first.. the basics.

Relay
--------

a relay is a device used to connect up a power supply or connection indirectly.

here is your basic relay:



this is what the ppins look like on the bottom and their typical numbers:




Now if this is new to you, listen up as here is the important part..

here is a diagram showing how these parts connect up inside the relay case:



EXPLANATION - When power is supplied across pin number 85 and 86, the electromagnet (the box with the diagonal line through it) makes the little arm change from connecting 30 - 87a to 30 - 87.

but when the power is cut off from 85 and 86 the arm springs back to its original position of connecting 30 - 87a.



Now the reason we use a relay in this project is because the Ballasts which power the Xenon bulbs require a lot of instant energy when initially warming up the bulbs and so to prevent the ballasts from melting (potentially) your standard wiring we use a relay so we can connect it straight to the battery (see the diagram at the end).

So if anything does go wrong, your bike's wiring will be safe.
And just to be extra careful we have even put an inline 30A fuse.



Now moving onto the next part

Ballast:



These come in all shapes and sizes, too many to mention. The above ones are Matsushita Ballasts with the connector to attach to a D2S bulb.
You will also notice there is another connection plug there, that is where the wiring from the battery is connected.


Bulbs:



Now this is a D2S bulb, or more specifically a Philips 85122 bulb.
This is a proper HID bulb (not the cheap aftermarket ones you get which have a base similar to a halogen bulb)
Notice the round base, this fits perfectly with the matsushita ballast.

This bulb will give you a 4300K colour temperature... again bulbs come in different colour temperatures.. but 4300K is used by manufacturers all over the world and has been tested and recognised as the perfect road colour for on the road (the most white without looking blue).

Now the fun part.

Bi-Xenon projectors:



This projector is different from all the other projectors.
Inside every projector there is a shield, a piece of metal that runs across on the inside of the projector... This is what gives you that sharp flat cut off line you see on the road. (also the shield is also responsible for the blue flicker you see on HID lights ).

Now a bi-xenon projector has a shield, but the only difference is the shield moves.
It moves up and down to expose more/less of the projector which gives you, your high beam and dipped beam


look at the following pictures and you can see the shield in the middle of the projector moves down:






How this moves up and down is by the use of a solenoid, this is an electromagnet that works the same as a relay only this time its moving a bit of metal in the projector:

solenoid:




Now the diagram:

Ok i'm going to post up the picture I have made to describe how the wiring is done then i'm going to explain it... so pic:



Ok, now from the beginning.

The battery is connected to a 30A fuse... this is to protect the circuit from surges and anything that might go wrong, so nothing is damaged on the bike.

The fuse then lead to a relay, this relay is powered by the headlight connection.
So this means if your headlights come on (when you turn on the engine) the relay will connect the power from the battery all the way to the ballasts (one for each headlight) and without interfering with the standard wiring.

Also you will notice that the relay also passes the power to another relay..

This is then powered by the high beam (flash) connector.
so when you flash / put your high beams on this will connect the power from the battery through the first relay and onto the solenoid of the projector (note you will have to connect this to both solenoids... I have only pictured one).

so a quick run down, when you headlights are turned on the ballasts will turn on

when you flash your lights the solenoid will move as to produce the high beam patter from the projector.


As said this is a basic set up... You can change what products you use and how you wire them up.

I've very good with electronics and stuff and I could make a little module with the 2 relays and the fuse in it and it would be no bigger than the size of a packet of cigarettes.

If you have any questions feel free,

Otherwise, I hope this helps anyone wishing to do this mod.

Steve
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post #2 of 31 Old 01-17-2012, 12:53 PM
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Really Great write up thanks Steve!!

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post #3 of 31 Old 01-17-2012, 12:57 PM
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Once again thx steve quick question tho the solenoid ? Thats comes with the projectors right? Its part of it? And im going to need two relays right?
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post #4 of 31 Old 01-17-2012, 01:07 PM
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nice write up man
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post #5 of 31 Old 01-17-2012, 01:09 PM Thread Starter
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yes, if you get a normal projector there will be no solenoid, if you get a bi-xenon projector it will have a solenoid.

Yeah you will only need 2 relays, you just need to make 2 wires go to each, instead of having a relay for every ballast and a relay for every solenoid you can have one relay for both ballasts and one relay for both solenoids.

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post #6 of 31 Old 01-17-2012, 03:18 PM
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Great write up on my set up you only need one relay if you are running bi xexon

projectors. Cause from the one relay you can run both power wires and ground to both

ballast. Then run the solenoid wires run to the high beam. That is how I have mine ran.
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post #7 of 31 Old 01-17-2012, 09:30 PM
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Is that the stock HID projectors on the zx6r? What model year?
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post #8 of 31 Old 01-17-2012, 10:57 PM
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great write up

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post #9 of 31 Old 01-18-2012, 04:49 AM Thread Starter
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Quote:
Originally Posted by Hotjujube View Post
Is that the stock HID projectors on the zx6r? What model year?
No the ninja doesn't come with a HID projector, they only come with halogen projectors.

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post #10 of 31 Old 01-18-2012, 05:35 AM
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Quote:
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No the ninja doesn't come with a HID projector, they only come with halogen projectors.

Steve
Hey Steve, what about 07 08?
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post #11 of 31 Old 01-18-2012, 06:46 AM Thread Starter
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Quote:
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Hey Steve, what about 07 08?
Unless the bike come with a standard optional extra for HID lights then no.

There are very few projectors out there that do both halogen and xenon bulbs.

As far as I have seen all the projectors used on the ZX6R including mine the most up to date model they are all halogen projectors designed for halogen bulbs.

I have posted another thread giving all the information I know about Xenon's here:

--> CLICKY

I hope this will help anyone who has questions.

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post #12 of 31 Old 01-18-2012, 12:09 PM
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Nice write up! I'm going to have to look into these

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post #13 of 31 Old 01-24-2012, 02:30 PM
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hey steve thanks for all the info just woundering if you have converted you 09 zx6r to bi xenon and if u had details of what bits i need and were to get them from? also whats involved in doing it

cheres gamo
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post #14 of 31 Old 01-25-2012, 08:46 AM
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I wonder how hard it would be to fab up a harness that did all the interconnecting between the battery, stock light plugs and ballast? That is the only thing keeping me from going dual bi-xenon HID. I am too lazy to make that...lol
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post #15 of 31 Old 01-25-2012, 11:37 AM Thread Starter
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Quote:
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hey steve thanks for all the info just woundering if you have converted you 09 zx6r to bi xenon and if u had details of what bits i need and were to get them from? also whats involved in doing it

cheres gamo
Gamo, unfortunately I have not, i'm currently spending my pennies on getting the bike back on the road, but it will be something I will be doing in the near future.

I could give you a details description of what would be required to do such a process, but as I said its time consuming plus it involves splitting your headlight apart to change the projectors.

Quote:
Originally Posted by Vampyre View Post
I wonder how hard it would be to fab up a harness that did all the interconnecting between the battery, stock light plugs and ballast? That is the only thing keeping me from going dual bi-xenon HID. I am too lazy to make that...lol
well you can, its very simple.
I did lots of standard plug and play wiring harnesses for Vauxhall Astra's in regards to HIDs.

All the plugs you see on bikes are standard type of connectors, all you need to do is source a supplier. For example I can get all the connectors for my Astra from Würth.

You could do a basic set up on the headlights but I would recommend you change the projectors to Xenon projectors as the standard projectors are designed for halogen bulbs.

HTH

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