NX headlight mod (swap)

I love the NX, but the existing headlight absolutely SUCKS! Since this is the bike I use when it is raining, it is especially important for me to get a better headlight setup installed. I considered installing a HID kit in the existing headlight, but the problem is that you loose your ability to switch between low and high beams on a single light setup. I decided that a newer dual-headlight setup would be a better option, since I could then install a HID kit on the low beam if I wanted.

While considering some different lights, my friend Tom mentioned that he was getting rid of the street parts for his RS250. I knew this was a cool-looking twin headlight setup, so I had him bring it over. After checking it out I decided to try and fit it. I really like that the new light is an ellipsoid low beam and projector high beam. I may look for a replacement front cowl for the bike, just in case I do not like the end results. Either that or I can go with a streetfighter look with the NX :)

Here is the stock NX front/headlight:

Here is the Aprilia RS headlight:

I think the new light will fit pretty well and should not be to difficult to install, though I am a bit concerned about putting too much of a demand on the NX electrical system. Perhaps I'll remove the front fairing and install the light streetfighter style, and run the bike for a week or two, to see how it all works. If it is good, then I'll cut and fit the fairing back on the bike.

 

Version 1.0
Removing the stock light:

 

Size comparisons between the lights. They are actually closer than I expected. The one thing that may be difficult is how much deeper the ellipsoid side of the new light is compared to the stock light.

 

The area I have to work with:

 

Here is the new light temporarily fit into the approximate location. I did have to move a few things, but it does fit quite well.

 

A final look at the space, temporary fitment of the light (no, the zip ties are not permanent). I removed the back rubber boot from the low beam to give myself some more room. The duct tape seal is temporary as well. For the wiring, I removed the connector from the bike harness (old and crusty), but left the pins installed on the new headlight wiring. This gave me an easy way to connect them, which I then sealed with shrink-wrap tubing.

 

Some shots of the light mounted and with the low and then high beams on.

 

It seemed like the light was going to be in the way of the speedo cable, though after getting the light in position and strapping it down, it turned out that the speedo cable does fit. Cool, that will simplify things.

 

I made a couple of simple brackets to hold the cluster in position for now. I can adjust or remake these once everything is in final position.

 

Some more shots of the light and cluster generally in position.

 

Ok, now the bodywork. To my surprise it actually fit really well. I can actually move the light outward a couple of inches which will give me more room for the proper low beam boot, speedo cable, etc. I will now test the charging system as well as ride it for a week or so to make sure that the lights are not going to be too much of a draw for the electrical system. Once I know the lights are staying, I will work on repositioning them forward, trimming the side covers to fit the corners of the lights, etc.

 

Oh yes, the final test. How does it all hold up to typical daily use :)

 

v1.1
Ok, after a break I am back to this project. Realizing that I needed all the space I can get, I re-routed the wiring harness so that it was under the front headlight frame.

 

Making a new mounting bracket.

 

Test fitting the new bracket.

 

Trimming the front fairing sides. I cut the first side and then made a template to match the other side. Both still took some final shaping, but I think it came out well.

 

Here is the final assembly. I still need to figure out a final mounting for the cluster, but the existing mounting is fine for now. I also plan to add a HID kit as well, and will update with pics when I get these done.

 

v1.2
I ordered a 5000k HID kit, though when I started to install it I realized that there simply was not enough room for everything. After considering different layouts, I realized that the stock cluster is just too large with the new setup. The main issue is that the stock cluster has the speedo positioned right over the ellipsoid light, which made connecting the speedo cable impossible. I tried shifting the clusterback enough for the cable to clear the light, but then the fork tubes would push on the cluster at near full-lock. I decided to replace the cluster with a single speedo, and a quick dig through my old parts boxes produced just that. It was also for a Honda, so the cable fitting and gearing were also the same! This single gauge could then be positioned in the center, allowing the cable to bass through the gap between the two lights.

This new setup also gave me more space to mount the aditional HID components. I fabricated a couple of new brackets which allowed me to securely mount all the components. I am not sure if the project will ever end, but ideas for v1.3 include making a panel to cover the components and allow me to mount the indicator lights.

As far as the HID light itself, I am very happy with it. I went with the 5000k since it seemed to have the highest amount of light output. The higher temperature versions (6000k, 8000k, etc) seem to sacrifice light output for the "coolness" of bluish or purplish headlights.