Kawasaki Versys 650 Fog Light Mount Bracket by alpy

Last crawled date: 3 years ago

Description
3D printable set for mounting cheap LED fog headlamp on Kawasaki Versys 650 (2015-). Maybe it fits Versys 1000, but I have not tried that.
Bill of materials
3D printed:
lamp_bracket_A.stl (1 pc)
lamp_bracket_B.stl (1 pc)
mount_clamp_for_console_rod_A.stl (2 pcs)
mount_clamp_for_console_rod_B(16).stl (2 pcs)
mount_clamp_for_console_rod_C(14).stl (2 pcs)
Purchased:
Screws: M4 x 16 Socket Head (stainless preferred) (10 pcs)
Washers: M4 (2 pcs)
Nuts: M4 (12 pcs) or Self-closing M4 (10 pcs)
Set of Headlamp from China, e.g. https://www.aliexpress.com/item/32855410119.html
Purchased and fabricated:
Aluminum/carbon fiber rod/pipe: Diameter=14mm Length=300mm
Remarks
These Chinese headlights are not the best option from durability point of view, so I recommend ordering at least 2 sets to make sure you'll have spare units in case they are needed.
Lamp mods
Protective cage has to be removed, we won't need it, however we'll make use of those mounting screws and washers, don't throw them away.
There are some instructions on the Internet about how to disable low beam and strobe modes. I strongly recommend applying that mod since that will make these lamps much more usable. (e.g. https://www.youtube.com/watch?v=bbjXatqFMxQ)
These headlight units may not be fully watertight despite sellers claim to be so. Use your creativity and find those weak points where water can get into the enclosure and apply the appropriate amount of silicone sealant gel to those weak areas. I'd recommend taking them apart and inspect/understand where would you need to apply extra sealing.
Sealing
As I mentioned above these headlamp units may not be watertight, so they need some extra sealing. This is valid for their mounting screws, so apply a small amount of silicone sealant gel on their threads before mounting units.
Electronics
For connecting these units to your bike you'll need some basic electronics knowledge and soldering skills, but describing them in detail is just out of scope of this project. I recommend connecting headlamps to accessory power circuit of your bike.