[2003_Sv650s]

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 ccasion14:

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 :naughty:

The projectors and shrouds:

Stock headlight low beam:

Stock headlight high beam:

Extra headlight pulled apart. Baked at 200°f 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 :highfive:

 

[Raffi D]

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.

 

[2003_Sv650s]

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.

 

[2003_Sv650s]

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

Ordering these: http://www.theretrofitsource.com/accessories/koito-bi-xenon-solenoid-pigtails.html#.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.

 

[2003_Sv650s]

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.
:disappointed: 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!!! ccasion14: ccasion14: ccasion14:

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.

 

[Starline]

Very cool, thank you for the detailed write up!

 

[2003_Sv650s]

Thank you! No problem. I try to keep record of stuff like this in case anyone wants to try it themselves.

 

[2003_Sv650s]

Update from this weekend: Project Complete :rock:

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.

 

[harryrat]

is it necessary to seal the projectors? Say if you had a naked bike, could you leave the projectors open to the elements?

 

[2003_Sv650s]

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.

 

[2003_Sv650s]

Bad image quality but it gives a good comparison:

Also now I've had my SV called Weebo and Wall-E

 

[2003_Sv650s]

Just had the bike out for the first time since "finishing" ....... aimed WAY too high. Guess I forgot that when I sit on the bike the rear suspension sags..... really disappointed that I have to take the headlight apart again to grind off part if the shrouds that hit the lens and don't allow for any downward aiming.

Definitely not in a great mood lol but such is life I guess

Hoping to get it done today and tomorrow.

 

[2003_Sv650s]

I just looked at this picture.............. I feel like an idiot. In my haste and frustration last night in the dark I was on the wrong adjuster.... I was turning that gray on near the center AKA the horizontal plane. In the upper outside corners of the projectors are the vertical plane adjusters.... Looks like I know what I'll be doing when I get home.

Maybe this won't be so bad if I can adjust just a little bit


Aiming for reference:

 

[neimis]

Hmm, you may want to revise those specs about how far down to aim your lights. Here are the specs from the Daniel Stern website http://www.danielsternlighting.com/tech/aim/aim.html :

headlight aiming @ 25’
lamp height (up to 80 cm. high) 3” down
(up to 100 cm. high) 4” down
(over 100 cm. high) 4.5” down

 

[2003_Sv650s]

Hmm, you may want to revise those specs about how far down to aim your lights. Here are the specs from the Daniel Stern website http://www.danielsternlighting.com/tech/aim/aim.html :

headlight aiming @ 25’
lamp height (up to 80 cm. high) 3” down
(up to 100 cm. high) 4” down
(over 100 cm. high) 4.5” down

The image I pulled was a general aiming I found that's referenced quite a bit on hidplanet.com

 

[neimis]

The image I pulled was a general aiming I found that's referenced quite a bit on hidplanet.com

Now I know why I get blinded by all the ricer cars! LOL, just kidding.

I've found that even after aiming headlights on a wall, nothing beats fine-tuning it on a pitch black level road.

 

[2003_Sv650s]

Now I know why I get blinded by all the ricer cars! LOL, just kidding.

Yea those guys hate PnP users with a deep passion. The 2.5" drop I referenced isn't too far off the 3" that D. Stern recommends. The center of the projectors sit at about 80cm on the SV.


I think I got it aimed correctly last night! Fingers crossed. I marked my line on the wall and sat down hard on the SV. Saw where the cutoff was, adjusted accordingly, and repeated.

 

[2003_Sv650s]

Readjusted and took some pictures on my phone last night after it got dark. The phone took alright pictures but nothing spectacular. Just noticed the street light is on too lol

Front:

Width Right:

Width Left (Not great b/c of the street light):

Cutoff before putting it back in the garage:

Left of center:

Center:

 

[2003_Sv650s]

Also for reference here are the links to the stuff I used (all sourced through TRS during sales):

Harness: Morimoto H4 Dual Output
Ballasts: Morimoto XB35 (35w)
Bulbs: Morimoto XB D2S 4500k
Projectors: Ininiti G37 Sedan Bi-Xenon
Shrouds: Bullet B-Stock
Misc. Items: Dremel, Nuts & Bolts, Sandpaper, Grill Hi-Temp Spray Paint, Wire Ties & JBweld

 

[onecartel]

Nice to see a proper setup! Great job documenting the procedure. You are a fine representative of team silver/silly forks/black wheels/big luggage.

I just picked up a Ducati 749/999 halogen projector, just need to find the time to rig a mount up.