Kawasaki Z1000 Twin dual beam projector headlight conversion also fits ninja 250 KLE KLR by albine92

Last crawled date: 3 years ago

This is the bracket needed to convert the 2003 - 2006 Kawasaki Z1000 headlight from original reflectors, in to twin, dual beam projector headlights with Halos.
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I designed this from scratch after buying a KT conversion kit and being incredibly irritated at how much they were charging for a laser cut bit of steel with 3 screws and an immense lack of quality.
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I would recommend printing in ABS and at 75-100% infill. PLA will work but ABS has higher temperature resistance.
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You can see in the pictures the before and afters of the headlight. The projectors make a massive difference over the stock reflectors and also look amazing too.
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To build this headlight, you will need the following,
Two 2.5" dual beam projectors,
Two 80mm halos,
Two H1 LED bulbs. (Nighteye are one of the best on the market for both light output, colour and build quality. Please make sure the bulbs you get will fit into your projectors)
8 X M3 x15mm Cap head bolts.
M5 Tap, (pretty sure its M5, could be M6 though)
Loctite threadlock or other glue (to make sure the bolts don't vibrate out),
An oven,
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Below is a general guide on how to do the upgrade. It is to be used as a general guide only and i accept no responsibility for any damage, loss of value, injury or any other undesired outcome from the use of, or the installation of this part.
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Print the bracket,
Screw the projectors to the bracket,
Tap the 3 mounting holes,
Remove original headlight unit from your bike,
Put original headlight in oven at 190°C for 5-7 mins,
Split the headlight unit open,
remove the reflector,
screw in the bracket with your projectors on it,
put the 2 headlight unit parts back together gently,
put them back in the oven for 5-7 mins,
push the unit back together and make sure its sealed.
wire it up and put it back on the bike.
DONE.