makanouchi
Junior Member
1. Remove the headlights from the bike.
a. Remove inner plastic fairing cover
b. Remove the turn signals.
c. Disconnect all wiring from the headlight.
d. Remove the 4 screws holding the headlight assembly to the frame.
Now the whole front fairing should come lose
e. Remove the 5 screws holding the headlight assembly to the fairing.
The turn signal brackets also need to come off
2. Disassemble the headlight assembly.
a. Bake the headlight for 15-20 min at 200 degrees.
b. Using a flat head screw drive, pry open the clips holding the front cover
c. Cut the sealant as you pull the cover off, it will get messy if you don' cut.
d. Remove the 2 factory reflectors and save the 3 mounting clips for each
![IMG_09411024x768.jpg IMG_09411024x768.jpg](https://www.600riders.com/data/attachments/14/14945-d92cae1a66324e9a20aa6f691298bdf8.jpg)
![IMG_08481024x768.jpg IMG_08481024x768.jpg](https://www.600riders.com/data/attachments/14/14946-4a737c194cc3cf7aeea66712c80ba1e1.jpg)
3. Fabricate a mounting plate for the projectors.
a. Cut a template using whatever you can find around the house
![IMG_09981024x768.jpg IMG_09981024x768.jpg](https://www.600riders.com/data/attachments/14/14947-20f718d0d109cbcfe87715cefed3f655.jpg)
b. Transfer your pattern to the 1/8 inch aluminum sheet and cut
I used a gig saw with a metal cutting blade.
![IMG_09741024x768.jpg IMG_09741024x768.jpg](https://www.600riders.com/data/attachments/14/14948-61bb584e4837763c88f9504b90399dd5.jpg)
c. Test your mounting plate for accuracy
4. Paint all exposed parts black, I used high temp flat black from auto zone
5. Assemble the projector housing onto the mounting plate.
I used M4 x 50mm screws, nuts, and locking nuts.
M4 screw into the projector, and a nut on each side of the mounting plate.
![IMG_08661024x768.jpg IMG_08661024x768.jpg](https://www.600riders.com/data/attachments/14/14949-b9102633901b5d8c5cdad6f0ee2aad49.jpg)
![IMG_08651024x768.jpg IMG_08651024x768.jpg](https://www.600riders.com/data/attachments/14/14950-85ed119e7090a7aa30e954b4c7788cfe.jpg)
a. Remove inner plastic fairing cover
b. Remove the turn signals.
c. Disconnect all wiring from the headlight.
d. Remove the 4 screws holding the headlight assembly to the frame.
Now the whole front fairing should come lose
e. Remove the 5 screws holding the headlight assembly to the fairing.
The turn signal brackets also need to come off
2. Disassemble the headlight assembly.
a. Bake the headlight for 15-20 min at 200 degrees.
b. Using a flat head screw drive, pry open the clips holding the front cover
c. Cut the sealant as you pull the cover off, it will get messy if you don' cut.
d. Remove the 2 factory reflectors and save the 3 mounting clips for each
![IMG_09411024x768.jpg IMG_09411024x768.jpg](https://www.600riders.com/data/attachments/14/14945-d92cae1a66324e9a20aa6f691298bdf8.jpg)
![IMG_08481024x768.jpg IMG_08481024x768.jpg](https://www.600riders.com/data/attachments/14/14946-4a737c194cc3cf7aeea66712c80ba1e1.jpg)
3. Fabricate a mounting plate for the projectors.
a. Cut a template using whatever you can find around the house
![IMG_09981024x768.jpg IMG_09981024x768.jpg](https://www.600riders.com/data/attachments/14/14947-20f718d0d109cbcfe87715cefed3f655.jpg)
b. Transfer your pattern to the 1/8 inch aluminum sheet and cut
I used a gig saw with a metal cutting blade.
![IMG_09741024x768.jpg IMG_09741024x768.jpg](https://www.600riders.com/data/attachments/14/14948-61bb584e4837763c88f9504b90399dd5.jpg)
c. Test your mounting plate for accuracy
4. Paint all exposed parts black, I used high temp flat black from auto zone
5. Assemble the projector housing onto the mounting plate.
I used M4 x 50mm screws, nuts, and locking nuts.
M4 screw into the projector, and a nut on each side of the mounting plate.
![IMG_08661024x768.jpg IMG_08661024x768.jpg](https://www.600riders.com/data/attachments/14/14949-b9102633901b5d8c5cdad6f0ee2aad49.jpg)
![IMG_08651024x768.jpg IMG_08651024x768.jpg](https://www.600riders.com/data/attachments/14/14950-85ed119e7090a7aa30e954b4c7788cfe.jpg)
Last edited: