Puneet1

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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sunilg

DIY topic approved.

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ROCKRZ

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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chicane1879

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

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L.P.

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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Puneet1

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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