How To: KLX450R Headlight H7 Conversion

Slick_Nick · Post by **Slick_Nick** » 02:07 pm May 09 2012

Yes mine looks like that. I'll see if I can come up with something. I'm thinking of making a cover for the whole assembly.

Slick_Nick · Post by **Slick_Nick** » 08:15 pm May 09 2012

Had a look at mine, I may look into making an aluminum plate that affixes to those two screws and will block out the residual light. Then again, maybe not. While I did notice it, I dont remember it bothering me too much.

B737driver · Post by **B737driver** » 11:44 pm May 09 2012

Agreed. The amount of time I spend riding at night, it's probably not worth the effort. However, the covers that are on the OEM KLX assembly might work and they are cheap.

Post by **Varmint** » 08:14 pm May 29 2012

OK I'm the worst when it comes to electrical... I bought the same lighting unit but want to use it stock with the KDX light switch. How can I splice these together. The wires on the unit are: green, blue, brown, and white. My assumptions, green=ground, brown is for the parking light, white would go to the KDX yellow wire and blue to the red KDX wire.

Does this sound correct?

B737driver · Post by **B737driver** » 05:32 am May 30 2012

I cut the cannon plug off and spliced the wires with the existing kdx wiring. Can't remember which color went where and I'm out of town and can't look. I ran the park and normal light to the hot wire and I'm fairly certain the green wire to the kdx ground. I think slick cut the wire at the park light and just spliced in the normal light.

Slick_Nick · Post by **Slick_Nick** » 10:10 am May 30 2012

That is correct. Don't waste Your time on that stupid useless parking light. Just splice the two "hot" wires into the KDX stock wire, and the Ground wire to the other. This will allow both filaments to run at once. It's an AC electrical system So it doesn't matter which wire you use from the KDX as hot.

Post by **Varmint** » 01:54 pm May 30 2012

Where can I get the stock connectors that come with the KDX. When I do mods, I never compromise the existing parts so I don't want to cut the wires to install new connectors. I would rather just create a new pigtail. Any help would be appreciated.

gregp · Post by **gregp** » 02:09 pm May 30 2012

The thumpertalk link does not work - do you have another?

Edit: Nevermind. I found it here: http://www.thumpertalk.com/topic/859440 ... nd-how-to/

gregp · Post by **gregp** » 02:31 pm May 30 2012

I am ready to rewind my stator, but I am only finding 16 gauge or 18 gauge wire - no 17 gauge.
http://www.mcmaster.com/#motor-winding-wire/=hrgvv8

Where did you get 17 gauge wire, and would 16 or 18 work as well? I am also seeing spool lengths of 250-300 feet, yet you say that "several football fields" worth come off of the stock coil. Is 300 feet enough?

Slick_Nick · Post by **Slick_Nick** » 05:25 pm May 30 2012

The stock wire is very thin, hence why there is so much of it. Thicker wire yields more amperage at a given RPM, but less voltage than thinner wire. The inverse is true. 16-18 seems to be the sweet spot where you get the est of both worlds.

Post by **SS109** » 06:14 pm May 30 2012

I bought my wire off of Ebay. Here is the guy I used. http://myworld.ebay.com/tech-fixx/ He has about any gauge you could want, good prices, and fast shipping.

N8Strine · Post by **N8Strine** » 07:07 am Jun 12 2012

Where did you get the rubber straps to hold the headlight on?

Slick_Nick · Post by **Slick_Nick** » 09:21 pm Jun 12 2012

N8Strine wrote:Where did you get the rubber straps to hold the headlight on?

They come with it.

N8Strine · Post by **N8Strine** » 06:56 pm Jun 15 2012

Oh, I have a factory KLX headlight. Who makes yours?

Fieldie · Post by **Fieldie** » 07:50 am Jun 22 2012

Varmint wrote:OK I'm the worst when it comes to electrical... I bought the same lighting unit but want to use it stock with the KDX light switch. How can I splice these together. The wires on the unit are: green, blue, brown, and white. My assumptions, green=ground, brown is for the parking light, white would go to the KDX yellow wire and blue to the red KDX wire.

Does this sound correct?

Mine arrived today from Aliexpress - White - AUD29 delivered in just on two weeks. Schmick looking unit & can't complain about the quality or the price. I may not do the HID transplant as I ride during daylight hours & only ever putt home if I have left the home straight too late.

Mine was maybe more aesthetic reasoning as I've been riding with guys who have 10 year younger bikes for the last two years & the old girl does a pretty good job keeping up with them all. I thought I would give her a bit of a birthday! (spot the old boy on a budget!) I may do the HID at a later date when we look to take it to the next level.

Wiring - Agreed - bugger that park light off! My KDX ground appears to be black with yellow stripe, so have put that onto the Chinese green wire, by splicing the wire with connector that I trimmed off the KDX unit. The male/female connector for this wire is back to front compare to the other two wires/connectors on the bike. ie on the bike the ground has a female plug while the other two wires have males...
I spliced the white wire on the chinese unit to the red/yellow wire on the KDX & the blue wire on the chinese unit to the red/black wire on the KDX. I will start her up tomorrow - 2040 hrs here - & can swap the "blue" & "white" connected wires around to check which is hooked up to low & high beam. Feedback on aliexpress says the seal is crap so I too will look to put silicon around the inside & set her in place to keep moisture out...

For $29, I might even buy a green one as a spare... ...or maybe black... ...or...

shaunkdx · Post by **shaunkdx** » 05:30 am Apr 27 2014

Hey guys,
Just wondering if anybody has fitted this light to a kdx with stock forks - Is there enough adjustment in the rubber straps to allow for a tight fit?
Cheers,
Shaun

Slick_Nick · Post by **Slick_Nick** » 11:51 am Apr 27 2014

The straps will work on the stock forks.

shaunkdx · Post by **shaunkdx** » 06:12 pm Apr 27 2014

Thanks Nick

deltap · Post by **deltap** » 07:35 pm May 04 2014

morganid · Post by **morganid** » 12:59 am Jun 29 2014

I am new to this HID stuff. I saw a guy over on thumper talk doing this exact same thing. The difference is that he was double-stick taping a ballast to the inside of his headlight shroud.I have a klx look-a-like headlight coming in the mail. It has a HID bulb already installed. Do I need to get a ballast? Nick, did you use a ballast? I hope I don't need to get one. Does the bulb type determine wether I need a ballast. I am planing to do a stator rewind this week so hopefully I'll get similar watts as when You did it. Does the massive amount of watts eliminate the need for a ballast? Thanks.

Here is the headlight I ordered, except mine should be white.

http://www.ebay.com/itm/HEADLIGHT-HEAD- ... e0&vxp=mtr

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