Join Date: May 2004
Location: Great White North
Projector headlight conversion ALMOST complete...Need your HELP
I have never been pleased with the headlight performance of my ZX10R. I seldom ride at night, but the times that I have, I was dissapointed at how poor the illumination was. As many of you have done as well, I adjusted the reflectors, and used brighter bulbs, all with no success. I have an HID kit, and it definitely puts out more light but the light dispersion is poor in comparison to the HID projectors on my Honda S2000.
For my project, I ended up using the projector lamps from an '05 Yamaha R1. It took some trimming but it fits beautifully in place of the reflector on the ZX10R. I even retained some adjustability via the stock adjusters. Even though these projectors were not HID specific, the lighting pattern, and intensity is incredible.
Anyhow, I will post pics and a brief step by step once I complete this project. However, I have one last problem that I need to solve and I hope someone might have an idea here.
The bulb mount on the R1 projector is a little longer than the ZX10R's and extends farther out the back of the headlight unit. As a result, I cannot use the stock screw on headlight caps to seal the unit. I could cut out a 2 3/8" hole in the cap, and it would fit perfectly. The problem is, the gaps will let in debris and water into the headlight unit housing and that is unacceptable.
Thanks guys! I have been staring at this for far too long, and figure someone with a fresh perspective might see something I am missing.