Sharing this with my Busa family on a couple forums;
Well the HID projector setup finally came in last week. I took a couple hours today and did the install.
Finished product looks good and I like the setup. Install did take some effort and I will detail the hurdles. Of course will post a test of lighting output once I finish the wiring.
I ended up ordering an Ebay setup for two bulbs (kit) as price was more competitive then the dedicated bike kits, looks like identical product.
Review: HID projector, "drop-in" installation for replacement low beam bulb. Basically is a universal (H7) projector that has a small base which fits into the stock low beam hold. It's long enough to bring the projector outward and small enough to clear the lens.
Quality: Decent quality but haven't tried the power on yet. Came with wiring harness, ballasts (large size that'll I'll be swapping for slim DDM version) some silicone glue and misc. nuts and bolts.
The chrome on the projector is good and the build quality seems to be fine for a Chinese made product.
I ordered the 5000k HID bulb with White angel eye setup.
Stuff you get with the kit;
Step 1: Take apart your busa front fairing and remove headlight. If you can't do this with info from this site you may want to reconsider this mod as it gets more technical from here.
Step 2: Remove all rubber bushings as headlight will go into oven.
Step 3: Put headlight into oven, I used preheat 250 degrees for ~5 minutes.
Step 4: Gently pry with butter knife (glue is sticky so don't use a good knife) the lens from the base housing. I used a screwdriver to wedge the latch parts slight open and then used the knife to seperate.
Step 5: Handle the lens carefully as you want to keep it clean.
Step 6: As per projector instructions, take apart retainer ring, locking washer and screw mechanism.
Step 7: Slide projector into hold and put back retainer ring, locking washer and screw mech. As per marking, orientate projector with TOP sticker pointing up.
Step 8: Tighten screw mechanism and use pliers to tight further. Keep checking front for straight alignment before tightening.
Step 9: I routed the angel eye wiring around te reflector housing and back out the bottom OEM projector hole (Hi beam hole in back).
OOPS, CUSTOM MOD NEEDED:
When I test fit the lens back on the housing the reflector ring touched the projector bulb. It wouldn't seal correctly. Out came the dremel.
Step 10: Lightly grind down a small groove on the lens silver reflector ring (the ring that normally covers around the stock high beam).
Picture:
Keep test fitting and grind slowly. I did it well enough that you can't notice the grind from the outside when headlight is put back together.
Step 11: Put lens and headlight setup back into oven for 5 minutes to soften glue.
At this point I used the grey goop that came with the projector housing. I do not suggest you use this as it's not the same as the OEM glue, it's simply grey silicone. Does the job fine but takes away the tackyness of the factory seal.
Step 12: Silicone outside of lens / headlight housing to prevent any leaks.
Step 13: Let dry.
Step 14: Reassemble headlight into front fairing.
All done for now. Next is to wire HID setup and provide you with some tests of light output. For now just enjoy the pics and check out my cool pearl Orange paint job on the nose
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Total cost was about $135 for 2 x bulb setup, Busa will use just one and other will be sold to buddy.
