Headlight Retrofit (G37 sedan projectors) - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

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Old 06-29-2015, 07:06 AM   #1
2003_Sv650s
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Headlight Retrofit (G37 sedan projectors)

I've decided to tackle a retrofit. Being someone that can never leave something the way it is this seemed like a task worth taking on.

I'll be putting bixenon G37 sedan (3") projectors into my sv650s. I bought an extra headlight, just in case I mess up or I need something to test on. I will be using the new xb35 ballasts and xb bulbs at 4500k from the retrofitsource. The shrouds are b-stock bullet from closeout section although I'm yet to find anything b-stock about them.

The plan as of right now today is to paint the stock reflectors black. The shrouds will be either left chrome or painted 2003 silver. I would like some opinions on this from you guys and gals

If successful I may retrofit the second light and sell it. So keep your eyes open!

Here are some pictures of my bike just to post them



The projectors and shrouds:



Stock headlight low beam:


Stock headlight high beam:


Extra headlight pulled apart. Baked at 200f for 10min:


Front end disassembled:


Test station (To make sure all components are functioning correctly):


G37 stock low beams (Not aimed or tuned, just resting on cooler test station):



Reflector #1 trimming:


Shrouds will need some serious trimming eventually:


More to come in the following weeks! I plan to tune the projectors a little more so that'll be fun. I'd love to have this done by the 18th but who knows.
All feedback is welcome (positive and negative)!
Please leave comments
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Old 06-29-2015, 04:35 PM   #2
Raffi D
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Re: Headlight Retrofit (G37 sedan projectors)

I'll be keeping an eye on this. Is it more cost effective to do this vs buying a kit on bkmoto? I thought that was a fairly priced kit when i looked at it last. And theretrofitsource had some higher end parts so i know they're not that cheap.
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Old 06-30-2015, 06:58 AM   #3
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Re: Headlight Retrofit (G37 sedan projectors)

Cost effective: Not necessarily. Then again the kit offered at BK and what I've got going on are pretty different. BKmotos kit, like the TRS kit, is a H1 bulb. From my understanding this bulb isn't a "standard" bulb. I can tell from the photos BK uses a generic H1 projector. Not saying that won't work though! Both TRS and BKs H1 projectors will plug right into the H4 socket of the SV, which is extremely convenient.

The projectors I am using come off a G37 and use a D2S bulb. Which is one of the more common HID bulbs that car manufacturers use. TRS offers a D2S kit but I saw a few of these G37 projectors being used on HIDplanet and decided they were worth the extra work.

The BKmoto kit is $219 with 1 shroud option. The TRS is upwards of $270+ depending on shroud choice. If you decide to use TRS, piecing the kit together would probably be cheaper. I frequented their closeout section all the time for deals as well as the for sale section of their forum. Members there often have excess HID parts.

I'm into this build about $280 right now including small miscellaneous things. That includes butyl glue to reseal the headlights, JBweld, Nuts and Bolts. I sat and waited for a sale or two before ordering everything, so that helped with cost reduction.

Also! No updates today.
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Old 07-01-2015, 07:32 AM   #4
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Re: Headlight Retrofit (G37 sedan projectors)

Sorry no real update today either. Been dealing with some house problems.

Ordering these: http://www.theretrofitsource.com/acc...l#.VZPK-_lVhHw
Need longer pigtails and these come with the 9006 on them. Perfect!!

This weekend I am planning to work on this a bit. Will take pictures of the process and post when I can (Might end up being Monday @ work, my home computer is super slow)
- Cut off the secondary shields
- Play with spacing of the lens
- Tune highbeam
- Dremel 2nd reflector
- Drill bolt holes in reflectors
- Figure out how I'm going to put them on the bike and aim
- Paint reflectors

Question time!!!
- Anyone have any opinions on the color choice I'm going with?
I think black reflector with color matched silver shrouds will look sick.
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Old 07-06-2015, 06:42 AM   #5
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Re: Headlight Retrofit (G37 sedan projectors)

Big Update!!!

Took apart the projectors and cut the secondary shield to eliminate that weird dim spot along the cutoff.
Before:


After:


Before:


After:



Side 1 Mock Mount



Both Sides Mocked up



Painted Reflector Bowls Matte Black


Test fit again. I did a lot of these.


Output


Color Flicker


Cut shrouds with dremel and mocked up. Chrome doesn't look too bad since the driving light "shrouds" are chrome.


Held lens in front of reflectors and realized I took too much off the top.
So............ I decided to do this:



JB Welded the nuts and bolts that I mounted the projector with




Used one of the pigtails on the solenoid to test out both projectors hi beam function. These shots are out of alignment as the reflectors were resting on a cooler and not in the bike.

Right Low Beam


Right High Beam


Left Low Beam


Left High Beam



Considering I don't have clear lenses on these the color isn't all that bad. The high beams work great. Please leave any comments or criticisms! All is appreciated!!!

Teaser for the next update. Probably will be completed next weekend I hope.


Also I still have the other headlight apart. Once this one is done I may retrofit that one. It's seen better days as it has 2 broken tabs and some scratching on the lens. I keep looking at TRS closeout section for something fun and cheap. Would love to do an LED retrofit, maybe with Corolla Projectors but the price is too steep for me since I don't think there would be much interest.
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Old 07-06-2015, 06:13 PM   #6
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Re: Headlight Retrofit (G37 sedan projectors)

Very cool, thank you for the detailed write up!
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Old 07-06-2015, 08:16 PM   #7
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Thank you! No problem. I try to keep record of stuff like this in case anyone wants to try it themselves.
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Old 07-13-2015, 07:15 AM   #8
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Re: Headlight Retrofit (G37 sedan projectors)

Update from this weekend: Project Complete

Friday:
JB welded on the shrouds without a problem.

First I tried to see how well the lens fit and completely scarred the shrouds. Luckily I cut a slit in cardboard and sprayed it without hitting anything crucial. Recessed the reflectors by grinding down a mount. Took it down as far as I could.

Went to mount AGAIN bolts hit and cracked a reflector... JB welded the reflector and cut them or drilled a hole in the housing. Now the lens still hits the shrouds but I can at least seal the headlight. Maybe not all the way closed. Will need to try tomorrow to heat up glue and seal.

Saturday:
Decided I wasn't going to half-ass at the very end of this thing. Needed to do it right. Took down the mounts even more to give me as much room as possible to avoid hitting the lens. Mounted and sort of aimed everything.

Ready to seal the projectors up!!!


Wiring:
This changed after trying to mount the first time. The oversized gsxr forks hit the ballast input/output connections.


"Finished" lol I need to improve my wiring but I WILL NOT be taking these headlights apart again.




Low-Beam @12ft:


High-Beam @12ft:


In the coming days I will get a night shot near a wall & in an empty parking lot. I keep saying it but please let me know what you guys think. If you are planning to do a retrofit like this and have questions please post here or PM me.
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Old 07-13-2015, 11:09 PM   #9
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Re: Headlight Retrofit (G37 sedan projectors)

is it necessary to seal the projectors? Say if you had a naked bike, could you leave the projectors open to the elements?
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Old 07-14-2015, 06:39 AM   #10
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Re: Headlight Retrofit (G37 sedan projectors)

Quote:
Originally Posted by harryrat View Post
is it necessary to seal the projectors? Say if you had a naked bike, could you leave the projectors open to the elements?
I'm sure that you COULD, but it really isn't a good idea. You'd probably be changing things out very very often due to dirt/debris/rain/moisture. HID bulbs can be finicky and just a touch of your finger on the bulb can drastically shorten it's life. If you're talking about just the front of the projector you would be replacing lenses very often. A chip in the lens can alter your output and cause unwanted glaring.

I would recommend on a naked maybe finding the deepest headlight bowl that you can and using the most shallow projector you can (I think it is the mini H1). The other option is an LED style sealed 7(JW Speaker/Peterson/etc.).

Hope that was a little helpful

I still need to put dust caps back on mine. That is something I'll do this week/weekend.
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