Here is the HOW-TO:
*DISCLAIMER* I am NOT responsible for any part that you might break, bend, scratch, melt or some other damages if you follow what I did. I did a lot of mistakes, I'll try to explain, please take what you consider good and use common sense.
first question first:
I got this kit:
http://www.theretrofitsource.com/product_info.php?products_id=221
and:
http://www.theretrofitsource.com/product_info.php?products_id=103
from theretrofitsource.com
Matt there was really helpful and I literally changed with him tens of emails, never let me wait or ignored me. I don't know if I would have had the patience the other way around
I got these projectors because are the smallest I found, they have warranty, the CS was really good, the reviews on the internet are positive.
now back to Versys.
I wanted to do this upgrade since I got my bike last year, but it was expensive and I didn't see anybody doing it before ( this is my first retrofit).
I studied how I can put one or two projectors, how can I connect them...
last year I bought a xenon kit with light bulbs and ballast and it was an improvement over stock, but the pattern on the road was kind of U shape, with the sides getting more light but the front kinda' missing...
I noticed a lot of people lately putting this xenon light bulbs in halogen housing and giving a LOT of glare, I even started to flash them... and then I was using the same
so here I had the chance to change something and improve my lights and the bike.
I put all the pictures at the end.
1. Remove headlight
Not difficult, remove fairings and headlight, some screws and unplug the connections
2. Remove everything from the headlight ( connectors, covers, park lights)
3. Heat the oven at 200F. After the oven is at the temperature, put the headlight inside ( I use a piece of wood) for 5-7 minutes.
4. remove the headlight from the oven. It is warm, I was able to pick it up with my bare hands.
5. Start cracking open the front glass from the body. I used this pry bar to open the small clamps and then slowly pulled the glass. It works very well, please take your time to open. I did it 2 times already and it’s not that difficult.
6. Installing the CCFL: I won’t detail this, it is very well explained here:
http://www.hidplanet.com/forums/showthread.php?33917-How-to-Install-Morimoto-CCFL-Angel-Eyes
(you have to register to see it, but it’s a 2 min registration, I had to do it too
)
Drill the holes for Angel eye but don’t install it yet, you have to cut the shrouds before.
7. The shrouds are not fitting inside, so you have to cut them. I just went slowly until I got the shape to put the projectors in.
8. These projectors have a nice way of mounting, you can fit them directly through the hole of the light bulb and have a thread that fixes them on the mirror. I did this and found that is not working well on Versys; the headlight is too short and when I put the glass back I broke an angel eye
. Also I had to back up the mirrors until the end and when put back on the bike I noticed that they were shooting to the sky
9. Back to work… I had to find a way to adjust the projectors inside the headlight, other than the adjustment from the bike.
Here is a way of doing it, cutting the mirrors and fix the projectors with epoxy.
http://www.hidplanet.com/forums/showthread.php?37877-How-To-Do-a-Retrofit
10. I wanted more flexibility of adjustment, so I started a design for a plate to hold the projectors. As you see in the photo, with just the plate, it doesn't look nice
. So I had to start cutting the mirrors...I even cut the mirrors supports to bring the mirrors further back.
I used a rotary tool. Do it outside if possible, with the wind from the back
Here are some photos with the plate at the end ( what I have now on the headlight). There are some extra holes and some unnecessary cutting ( part of finding the right shape).
I scanned the plate with a scanner so if you print this with no rescale you should have it in the right shape, just cut and fit
11. The base of the projector has 8 holes: 4 for shroud and 4 for the support of the lens. I used the holes for the support ( M4x0.7) and I replaced the bolts there with SS bolts M4x0.7x50mm ( very hard to find, BTW….at least here..)
12. I installed the projectors through the mirrors and fixed them with 2 locking nuts on the plate. I have now the possibility to adjust them individually in all the directions. (Be careful with the wires when you fit back the projectors, I almost cut them
)
13. The factory adjustment is using 3 bolts. One for up/down, one for left/right and one for depth. I used the same bolts for major adjustment. I put back the plates and the plastic nuts used by the factory adjustment.
14. The projectors are aiming lower now and have bigger distance from the glass. I can install the second angel eye ! yey! ( I don’t have it yet..
)
15. I put back everything, and put it back in the oven for 5-7 minutes at 200F. Clamp it after for the silicone to harden.
16. Mount the light bulbs and city lights ( if you have)
17. Fix the ballast on the frame ( I had mine from the previous kit, slim ballasts, you can buy the same ones with the kit from theretrofitsource.com ) I used tie-raps.
18. Put back the headlight and connect the wires. I used the old H4 base for the top projector. I have to bring a wire from the battery for the bottom projector with a fuse and a relay, I want to use only one most of the times. The high beam is very easy to connect, I used this cable and plugged it in the lower H4 female connector. It activates the solenoid on both projectors for passing and high beam.
19. Adjustment: don’t do like me
I put everything back, sealed the headlight, put it on the bike and adjust the top projector; everything is great, but the lower projector is aimed a little low… so now I have to open the headlight again ( it’s not that bad, I wanted to install the second angel eye also
)
Use this approach: after fitting the projectors in the headlight and the ballasts on the bike, put the headlight ( without the glass) on the bike and adjust the projectors. When you have everything ready, put back the glass….
20. The angel eyes I connect them to the city lights, I have the connectors from easternbeaver.com. You can connect 2 angel eyes to one CCFL inverter.
I hope it’s not that difficult and I put all the details :yeahsmile:
Enjoy!