Gen 5 HID/LED mini projector Install - Kawasaki ZX-10R.net
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post #1 of 16 Old 08-20-2019, 10:43 AM Thread Starter
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Gen 5 HID/LED mini projector Install

so this isn't going to cover all the crap that is taking the headlight assembly off of the bike so much as just giving people an idea of how easy it is overall as long as you take your time and don't forget you put part of your bike in the oven. You absolutely will melt tabs or deform the assembly if you go too hot or too long or both. Placing the assembly directly on a rack and not on at least a cookie tray will leave marks in the plastic, once you separate the assembly it is important to place the lenses inside facing down to prevent dust from settling on the inside of the lense. Don't touch the glass with your hands and that's the rough stuff, now some pics and explanation of them.
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post #2 of 16 Old 08-20-2019, 10:45 AM Thread Starter
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place the oven on 230f and allow it to fully preheat.
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post #3 of 16 Old 08-20-2019, 10:47 AM Thread Starter
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while preheating, gather oven mitts or leather gloves, a flat head screwdriver and possibly a second one, Set a timer for 7 min and place the assembly in the oven. Check in on it after about 2 or 3 min to make sure it isn't sitting on a lense and that the whole deal is roughly level and stable, try and keep it as centered as possible and away from the walls of the oven.
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post #4 of 16 Old 08-20-2019, 10:51 AM Thread Starter
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After the 7 min you need to remove the assembly and place on a soft surface that won't Mar or scratch the now softened plastic. Starting from an outside corner pry the two halves apart, you can use two flat head screwdrivers to help make this happen quicker. Once the corner is pried up quickly go around and gently pry anywhere that the lock tabs are while leaving the first screwdriver in the corner already pried up. Now with your hands grab the assembly and separate by pulling apart. It should only take you all of 2 min to do this without damaging the assembly. Place the lenses aside and place the lights back in the oven for another 2 min to replace lost heat.
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post #5 of 16 Old 08-20-2019, 10:52 AM Thread Starter
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obviously it is a repeat of the first side. I couldn't take pics and still do it without making a mess or ruining my lights so use your imagination, this is what it should look like when done.
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post #6 of 16 Old 08-20-2019, 10:57 AM Thread Starter
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While apart I got a clean cloth and a lil rubbing alcohol and gave the chrome part a wipe down, after it dried I spray painted the chrome a Matt black. no need for the chrome with the projector instead. start by just misting the whole deal and waiting a min or two for the solvent to evap. After that must a couple more times, this ultra light coating will help prevent birds eyes and runs from forming. it just allows this to be done without having to scuff and then clean the chrome. I have a green enamel high temp engine paint I wish I had used but it is at my friend's from painting the radiator gaurd so black it will be. Just do lots of light coats and let it slowly get to the color. you don't want a run or a thick paint job or it could chip and look like shit. not worth rushing this part. here is a pic of it after painting
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post #7 of 16 Old 08-20-2019, 11:07 AM Thread Starter
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once dry you will need to install the projector units, for this I only used the thin silicone washer/gasket and the little steel retainer that came with the projectors. You should remove the stock retention clip by loosening the one Philips head screw and also remove the retention clip on the projector so that you can unscrew the retention nut. in the pic from left to right is the silicone washer which goes on the projector before placing it into the assembly, then on the far right is the retention clip that should be slit over the threads once in the assembly. In the center is the nut that came with it, just take your time and be gentle to start so you don't cross thread the thing. The beveled side should be facing out.
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post #8 of 16 Old 08-20-2019, 11:08 AM Thread Starter
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this is the retention clip that goes on before the nut.
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post #9 of 16 Old 08-20-2019, 11:13 AM Thread Starter
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once I got both if them installed and looking level, making sure the cut off flap was on the bottom cause the light is flipped when it comes out of the lense like looking through a magnifying glass, I carefully set the assembly on my bike and plugged a light in, started the bike and checked the beam pattern for a correct cut off line that showed on the top. To do this you will need to reinstall the projector retainer with the 3 tiny screws, then insert the round plug deals that came with the led lights and clipped it down, now all you need to do is slide the LED directly into the attached hollow adapter and plug in the leads. Start the bike and aim at a wall, make sure everything is level with the bike if the bike was being held up at a stop light. I just used a screwdriver to flip the hi low flap down to check how my beam was going to show. once happy I pulled the LED lights and headed back to the oven. The pictures show the light pattern with the cut off flap closed then open for high beams. I'm happy.Last pic is after I pulled the lights and had it ready to go back inside
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post #10 of 16 Old 08-20-2019, 11:15 AM Thread Starter
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now is the time to install angel or demon eye LEDs or any other effects style lights in the assembly because once back together it's best to leave it that way.
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