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I have seen a few different methods that require making complicated mounting plates and spend hours and hours on adjusting the plates so the lights are correctly positioned and aligned.

This how-to will show the easiest method of installing hid projectors into the ninja 300, 90% bolt on, with almost no special tools needed, only basic hand tools and a dremel.

You will have both headlights on for low beams, and high beams, with super bright HID's and halo's

This project should take about a full day, or a nice weekend with lots of breaks.

Lets start!

Remove headlight from bike, remove light bulbs from the headlight.



Now, you will need to open your headlight.
This is the hardest step of the whole install, due to the fact that Kawasaki cheeped out on the ninja 300 headlight and saved 25c by using silicone based glue and not rubber butyl glue like every single other headlight on the market.
This glue doesn't get much softer with heat unlike butyl glue and its harder to remove the lens.

You will need to stick the screw driver deep into the seam and cut away the glue as you wiggle the screw driver, do this all around the headlight.

This took me about 45 minutes and i had the lens apart.

once the lens is off, scrape off the old glue.









Then remove the 2 screws on the back of the reflectors that hold the bulb holding hardware



Now remove both reflectors from the headlight by turning the 2 rear adjustment screws counter clockwise, and then pop them out from the 3rd mounting point which is a snap in ball. be gentle and turn each screw a few turns and go to the next. you dont want to strip the delicate plastic sleeves that the adjustment bolts thread into.



now we need to drill a small hole for the projector wires to go through,
drill from behind the reflector right under the bulb holder base.
the new hole is located under the center hole where the light bulbs go.


and now we need to modify the reflector with an easy cut, so the projectors will fit properly.
You need a dremel with a cutting bit.
Here is the end result of how the cut needs to be on the bottom of the reflector:




Here is a video that shows how to cut using a dremel, in this video i did not cut deep enough, use the above pics for reference how much to cut off.

***Disclaimer***
Wear eye protection goggles, and apply caution, Me nor BKMOTO shall not be responsible for any damages to you, your property or any other accidents, use this only for reference***



to be continued soon...
 

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I suspect you may be able to get a more accurate cut with the dremel if you were to cut using a cut-off wheel
 

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Discussion Starter #9
I suspect you may be able to get a more accurate cut with the dremel if you were to cut using a cut-off wheel
I have the cut off wheel as well, but i like the freedom of the cutting bit, this cut doesnt need to be exact, nor perfectly straight, so the cutting bit works fine.

All this trimming does is give more room for the projector so it will fit properly and wont be pressing against the reflector, so make the cut, test fit the projector, if its not touching the reflector on the bottom, then the cut is fine.

You will not see the cut at all once everything is blacked out and installed back into the bike.
 

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Discussion Starter #12
Where is part 2 :D
The rest will be coming soon, i am just extremely busy right now with holiday orders, so as soon as i have some free time i will continue this post.

take some photos of the nighttime visiblity.
Here is a quick shot i took of just one projector, its super bright, and with 2 projectors will be even brighter. take note at how well lit the far away trees are.

 

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Discussion Starter #14
Thats the low beam? Looks like it needs to come down a bit
Yes, its the low beam, dont mind the height, its just me holding the projector in my hand, once they are mounted on the bike you can fully adjust them with the stock adjustment knobs on the back of the headlight.
 

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^ its not just that. It's also the usability. Projectors aim the lights properly to light up the road. With projectors visibility is greatly increased with HIDs. If you just slap HIDs on the stock reflector all you will do is blind people and add tons of glare

Examples of projectors vs HID in halogen reflector (stock w/ HID kit)



The stock ram 1500 reflectors aren't too bad in this video at aiming light but most other reflectors do a terrible job.
 

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The rest will be coming soon, i am just extremely busy right now with holiday orders, so as soon as i have some free time i will continue this post.



Here is a quick shot i took of just one projector, its super bright, and with 2 projectors will be even brighter. take note at how well lit the far away trees are.

:eek:

Touche...nicely done sir! thank you :)

Thats what i call a nice cut off!
 
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