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HOW TO - KLX Headlight BA20D Bulb to H4 .

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Hi Guys, 

 

I've just received my KLX headlight that I bought on ebay, here's the link : 

 

http://www.ebay.ca/itm/Dirt-bike-Universal-Head-light-Suzuki-DR-DRZ-RM-650-200-250-125-400-80-65-85-70-/290749211397?pt=Motorcycles_Parts_Accessories&hash=item43b200e305&vxp=mtr&_uhb=1

 

Unfortunately for me it came with a BA20D light bulb so I had to do some modification to get it to work with the stock wiring of the DRZ . 

 

For those of you who have the same problem that I had, here's the HOW TO of what I've done to get it working .

 

Note : For this HOW TO I used a brand new H4 Bulb 

 

IMG_20140208_141417.jpg

 

Here is the pic of the headlight when I received it

 

 

IMG_20140207_183745.jpg

 
IMG_20140207_183801.jpg
 
IMG_20140207_183823.jpg
 
IMG_20140207_183828.jpg
 
IMG_20140207_184053.jpg

 

Step 1 : Remove all the wiring from the plastic piece until your left only with this .

IMG_20140208_141227.jpg

 

Step 2 : Enlarge the hole from the plastic piece so you can fit the H4 bulb in it .

IMG_20140208_142950.jpg

 

Step 3 : Fit the H4 bulb in the enlarged plastic piece, don't enlarge it to much so it will fit tight .

IMG_20140208_143039.jpg

 

Step 4 : You won't be able to push to H4 bulb completely in the plastic piece because of the metal around the bulb, remove the extra metal until it fit completely inside the plastic piece .

IMG_20140208_145419.jpg

IMG_20140208_150153.jpg

 

** If you want it to be tighter you can add some double face tape on the back of the metal part around the bulb .

 

Step 5 : One you've fit the H4 Bulb inside the plastic piece, you'll need to cut the back of the plastic piece to make it clear the H4 Bulb connector, like this :

IMG_20140208_150148.jpg

 

One all those step are done you can just fit the plastic piece back inside the headlight, this way it won't move and the bulb will be tight . 

IMG_20140208_150238.jpg

IMG_20140208_150230.jpg

 

Tomorrow I'll do the bracket to fit the Headlight, I'll do another HOW TO, Here's the result, it look as bright as stock and it was plug and play with the stock wiring .

 

IMG_20140208_170423.jpg

 

Hope it can help some of you guys . 

 

Sorry for my spelling, english is my second language .  :rolleyes:

Edited by Blooop
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Hi guys,

 

Thanks for the reply, after some research I think I found the solution, here's the link :

 

 

Overall, this guys bought and HID H4 Kit and the H4 HID Bulb was around 2mm too wide for the BA20D socket so he shaved the edge of the bulb and it fit like a charm .

http://www.supermotojunkie.com/showthread.php?130300-DRZ-400SM-3rd-Mod-The-Jump-to-HID

 

This one, the guy bought and HID BA20D bulb kit, and it fit right into the plastic pieces . 

http://www.supermotojunkie.com/showthread.php?139996-DRZ400sm-Headlight-Swap-Build

 

I've never looked at the DRZ headlight/bulb in details, so I was wondering is there a difference between and H4 HID Kit bulb and and H4 bulb. I'm thinking maybe I could just shave the edge of an H4 bulb to fit it in the BA20D socket and plug it with my stock DRZ wiring, just like the guy did with his HID H4 Kit . 

 

Do you think it will work ? 

 

Thank you !! :D

Edited by Blooop

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Hi guys, 

 

I got it working, I'll change my first post to make it an HOW TO, maybe it can help some guys on the forum !  :thumbsup:

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Hi guys,

I got it working, I'll change my first post to make it an HOW TO, maybe it can help some guys on the forum ! :thumbsup:

Always good to see a how to

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Hi guys, 

 

I got it working, I'll change my first post to make it an HOW TO, maybe it can help some guys on the forum !  :thumbsup:

 

Nice work, I am sure this will be helpful to others......

Instead of editing your first post maybe you should have just stuck it on the end so we could see a timeline...anyway well done..... :thumbsup:

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Hi guys, 

 

After 1 hour of work and 3 custom braket here is the final result, what do you guys think ?  :D

 

1654161_10152016939528271_1771003843_n.j

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Awesome thanks for the how to! Going to do this next week, just got my ebay klx light. Dou you have pics of the brackets?

Here's the bracket picture, it's really basic :

1920317_10152018724633271_588049046_n.jp

 

At first I've roughely cut 2 backet that I've bolt on my DRZ where the screw were going to hold the stock headlight.

Then I've put the KLX headlight on my DRZ just to see where the hole will arrive on the bracket that I've bolt earlier . Then I marked then with a Sharpie to know where I need to drill the new hole on the bracket . 

 

Once the top of the KLX Headlight was bolted I needed to figure out how to fit the bottom part . 

 

What I did is that I've bolt a bracket horizontally on the 2 bottom hole of the klx headlight .

1625656_10152018725033271_872381990_n.jp

 

Then on the bottom hole where the stock headlight screw was going, I've scew a bracket vertically .

Then I place the bottom bracket of the klx headlight at the back of the vertical bracket on the DRZ then I bold the 2 screw on the top bracket to hold it in place . 

 

This way in put a pressure on the bottom bracket so the bottom of the klx headlight won't move .

 

I don't know if it's clear .. I have a hard time explaining how I did without that much picture, feel free to ask question if you need and I'll answer the best I can .

 

Looking good! Any pics of the light output? Also how does it compare to the stock headlight output?

Here's the only pic of the light output 

IMG_20140208_170423.jpg

 

The output between the stock and the klx headlight is pretty much the same with the H4 bulb, I didn't see any difference .

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Hi guys, 

 

After 1 hour of work and 3 custom braket here is the final result, what do you guys think ?  :D

 

1654161_10152016939528271_1771003843_n.j

 

Neat from the front what's it look like from behind....?

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Bring on the HID kit....??.... :thinking:

I thought about the HID kit, but the stock light output was enough for me .

 

Neat from the front what's it look like from behind....?

I don't have any pic from behind but it's really clean, you don't see any wiring at all, you only see the two top corner of the headlight . 

I'll install my new handguard next week so I'll be able to take the pic from behind for you.

 

Here's some pic from different angle :

1901297_10152019945008271_751072331_n.jp
 
1911713_10152019945683271_466478108_n.jp
Edited by Blooop

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I thought about the HID kit, but the stock light output was enough for me .

 

I don't have any pic from behind but it's really clean, you don't see any wiring at all, you only see the two top corner of the headlight . 

I'll install my new handguard next week so I'll be able to take the pic from behind for you.

 

Here's some pic from different angle :

1901297_10152019945008271_751072331_n.jp
 
1911713_10152019945683271_466478108_n.jp

 

 

You can never have "too bright" of a head light....Night riding is dangerous, obviously due to reduced visibility ....HID also takes less watts..

I converted my lighting system to a combo of HID and LED and have practically turned night into day, ...

I have the same setup as per this thread....http://www.thumpertalk.com/topic/989008-led-and-hid-headlight-upgrade/?hl=+vagrantidol%20+lighting%20+system

Edited by Craigo 485sm

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You can never have "too bright" of a head light....Night riding is dangerous, obviously due to reduced visibility ....HID also takes less watts..

I converted my lighting system to a combo of HID and LED and have practically turned night into day, ...

I have the same setup as per this thread....http://www.thumpertalk.com/topic/989008-led-and-hid-headlight-upgrade/?hl=+vagrantidol%20+lighting%20+system

Nice lighting setup !

Habitually I don't ride at night, that's why I didn't really bother with the lighting ouput, but I'll take a look at the cost of an HID kit . 

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Hey everyone, just wanted to chime in with my experience! I followed these steps and it worked out great, got it to mount up nice and everything, the H4 fit nicely after i gutted the adapter.

 

BUT, after only having the light on for about 2 minutes I noticed it is melting the top of the clear plastic lens at the very top. I only noticed because it was smoking (-2 C here today). Do the HID kits run less hot? Not sure what to do to remedy the problem so I switched back to the stock lamp for the time being!

 

I have the cheap ebay model by the way.

 

Cheers fellas

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This looks like about 10 steps too many. I inserted the stock socket into the klx light and modified the metal clip to hold it in. Took about 15 min and then mounted it right up. Its been working with no melting for year. Just did a friends the same way.

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