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Thread: Opening Headlight of Apache RTR to install a projector

  1. #1
    Rusted Puneet1's Avatar
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    Default Opening Headlight of Apache RTR to install a projector

    Light output from majority of Indian bikes is very poor and it makes it dangerous to ride at night with the bad roads and drivers we have in our country . we will fix a bi xenon projector with a 35 watt hid to see better at night as hid provides nearly 3 times light than a halogen bulb .

    to retrofit the Projector inside we will have to separate the glass and reflector using a heat gun and then install it .

    This will work only with full dc bikes so make your RTR /other bikes full dc first else battery will drain quickly since hid runs on battery current and not alternator .

    Tools needed - heat gun [ if you want to buy local ones cost around 350 rs and branded ones with warranty approx 800+ ]
    spanners and screwdrivers
    and of course the projector and hid .

    first remove the headlamp assembly by unscrewing the marked nuts ,disconnect the bulb and pilot lamps connectors




    now remove these screws


    the sealant inside softens at a higher temperature and its located at the thicker portion marked in blue places so you have to heat this portion only









    now start heating the marked places and keep moving from place to place and dont concentrate the heat on only one area . after 10 mins see if sealant has softened and using screwdrivers try and pry open at the edges



    now concentrate on one corner and heat it well and then separate the glass portion . put in a screwdriver or something there so it doesnt seal back and like this separate the reflector completely.








    now install your projector and try to level it well while installing , the cutoff should be straight in lo beam .
    My projector was a plug and play type so not much hassle in installing it but you might have to make brackets for projectors that use bulbs like D2S etc[refer nanotechnology's thread ] .i also added a led flexible strip and its always on like a DRL . wipe the lens on the projector well with a microfibre cloth /glasses cleaning cloth as there might be fingerprints etc on them .



    now that the projector has been installed reheat the sealant around the reflector well and when it has softened well enough again [test its softness using a thin screwdriver etc ] put the glass back on .


    if still some gap remains between reflector and glass then keep heating sealant area and with some force you will get back to the factory level .

    if gaps around glass and reflector remains then sealing it with a butyl rubber sealant will be a good idea else moisture will creep inside in monsoon season .

    now also make sure the rubber grommet at the back doesnt have any gap so no dust can enter from there . apache rtr also has a small space where a HID ballast can be fixed and i have fixed it there with double sided tape so it doesnt move and cause vibes and rtr already has enough vibes .only the slim or medium sized Hid ballasts's ones will there the large sized ballasts will have to be fixed elsewhere .






    now enjoy riding at night !

    any suggestions welcome

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    Super Moderator sunilg's Avatar
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    DIY topic approved.
    (Been There Done That) x 3.25

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    Rusted ROCKRZ's Avatar
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    Wow.. All that i needed... Thanks for the info buddy. The last time, when i asked you about this, i was confused so could not get this setup done.. Now i am confident that i can get this setup on my bike...

    Thanks buddy
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    Very Nice DIY, Puneet. Would come in handy to many who are interested!!

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    I believe that there is still some clarity to be produced here, someone who doesn't know at all.

    I Still could not make out how that Projector came out of that small hole where old H4 bulb was put?
    Which projector and lamp is used?
    How will you make it possible to stay there on bumps?
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    Rusted Puneet1's Avatar
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    Quote Originally Posted by L.P. View Post
    I believe that there is still some clarity to be produced here, someone who doesn't know at all.

    I Still could not make out how that Projector came out of that small hole where old H4 bulb was put?
    Which projector and lamp is used?
    How will you make it possible to stay there on bumps?
    the base of the projector is threaded and a locking ring with a h4 type adaptor secures it .almost all aftermarket projectors are fixed this way . the attachments will make it clear .

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    Icon9 Re: Opening Headlight of Apache RTR to install a projector

    I have Apache RTR 160 (2015 model) and I want to replace my existing headlights with HID Projector lamp. But I am unable to see any of the photos uploaded by you. On each photo its showing a yellow frog saying "Click to discover imageshacks". Please help. And I also want to know that how much will it affect my battery and bike performance if I do not convert to full DC and will it affect Projector lamp also? I am going for "Bi-Xenon Led Projector Lamps with dual angel ring (blue and red), Is it fine or should i go for something else??

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    Default Re: Opening Headlight of Apache RTR to install a projector

    It says $25 gift card ITUNES. DOWNLOAD from play store. What the Heck is this please help me to view those images.

    If no one can view this its of no use... Please
    DrAgOn

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    Mir
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    Default Re: Opening Headlight of Apache RTR to install a projector

    Same thing is happening with me too. Can't view the images.
    May be the Original Poster should edit the post with fresh images.

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    Default Re: Opening Headlight of Apache RTR to install a projector

    no pic is visible to me too

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