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Old 08-14-2012, 11:08 PM   #1 (permalink)
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Default HOW-TO: Install BKMOTO BiXenon HID projectors with angel eyes halos 2008+ Ninja 250R

I have used bkmoto projector kits quite a few times for projector retrofits and wanted to post a complete guide on installation.
I have seen a few different methods on this site that require making complicated mounting plates and spend hours and hours on adjusting the plates so the lights are correctly positioned.

This how-to will show the easiest method of installing hid projectors into the ninja 250R, 99% bolt on, with no special tools needed at all.

this kit will fit the 2008 2009 2010 2011 2012 Kasawaki Ninja 250R 250

More information on this kit can be found on www.bkmoto.com

The kit will come with everything that you need to install the projectors, including all neccesary H7 adapters and H7 plugs which will plug into your OEM headlight plugs.

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.

Here are a few pictures from bkmoto.com website:





Projectors with optional demon eyes (available in red or blue)



Here is the complete kit:






Lets start!

Remove headlight, remove light bulbs from the headlight


[B]Now, you will need to open your headlight.
To do this you will need to heat up the glue that holds the headlight together.
You have 2 choices, Either use the oven or buy a cheap heat gun (about $25 at any hardware store)

Heat gun Method:
Turn on the heat gun on high setting, hold the heat gun about 8" away from the seam and work your way around the headlight seam slowly for a few rounds.

Oven Method:
Preheat the oven to 225F degrees, place the headlight on a towel and into the center of the oven.
Bake the headlight for 8 minutes at 225F degrees, then remove the headlight.

Once headlight is hot, start to open it using flat head screw drivers, carefully open the little tabs that lock the headlight together and pry the headlight open.

This is the hardest step of the whole install, due to the fact that Kawasaki cheeped out on the 250R 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.

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














Remove the 2 screws on the back, on both sides of the headlight and remove the hardware


Now you need to drill 2 small holes for the projector wires.
I drilled them after painting, you should do it before painting so you wont chip away the paint.
drill from behind the headlight right under the bulb holder base.



Painting the reflectors:
This step is optional, I opted to paint my reflectors matt black, as i like the blacked out headlight look.
If you plan on leaving the reflectors chrome, then skip this step.

To paint the reflectors you can either remove them and spray paint them or use painters tape to cover the headlight around the reflectors, then spray.






We are now ready to mount the projectors!

Remove the bulb holders and all hardware, except the silicone washer.



This is all the hardware you will need:
Silicone washer on projector, H7 adapter plate, locking ring and a lock nut.



Now we need to fish the two white halo wires and the red/black wires through the drilled holes.
The white halo wires wont have a plug on them, but the red/black wires will, and the plug needs to be removed.

To remove the plug, you need to insert a needle or a hair clip into the small opening in the front of the plug just above the pin, and press down untill you get the pin out.
This part is a little tricky, especially the first few times you do it.



here is the pin that you will be removing, look at the little flap in the middle, this is basically what needs to be pushed down inside the plug for the pin to come out.


Last edited by borka; 09-12-2012 at 12:15 PM.
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Old 08-14-2012, 11:09 PM   #2 (permalink)
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Fish the wires though the hole and insert projector into the light bulb hole.


Here is how the projectors need to be oriented, exactly like this on both sides


insert the H7 adapter plate




put on the locking ring


I recommend you now put locktite thread locker on the projector thread, to insure it wont get loose from the bikes vibrations.

Put the rear nut and tighten with needle nose pliers while holding the projector with the other hand.


Put the bulb holder back on


Your projector is now mounted!
Notice the slight gap in the halo ring at the bottom of the projector, this is how the projector needs to be oriented, with the gap facing down.


Now mount the second projector using the same above steps.


Projectors are mounted and are 99% oriented properly by the tabs on the H7 plates.
To those who want to have a perfectly matching cut off lines, you can power up the projectors, shine them at a wall at least 10ft away and turn the projectors until both cut off lines are exactly the same horizontally.
Insert hid bulbs into the projectors,
Use the supplied ballast test leads, connect the red/black wires from the test leads to the battery,
connect the ballasts to the light bulbs
Then connect the test leads to the ballasts
Once the bulbs come on, shine the light on a wall and if the cut off lines are not the same horizontally, meaning that one is straight across and the other one is slanted to the side, simply turn the slanted projector until the cut off line is the same horizontally as the other line.

Here is how you want to cut off lines to be:


Your projectors are mounted and you can seal the lenses,
make sure all the old glue is scraped off.
To reseal the lens you can use 3M Window-Weld Round Ribbon Sealer, found at a local Auto Parts store or ebay.
Or you can use silicone, if using silicone it will be extremely hard to reopen the lenses again if need be in the future.


put the ribbon in the headlight seam, the ribbon is very thick so just stretch it while inserting into the seam, so the seam is 50% full with the ribbon.

You need to heat up the ribbon using the same steps above as when you were opening the headlight.

Once glue is hot, press lenses together tightly, and clamp them together untill the glue cools down, or wrap tightly with masking tape around the headlight to keep it closed.

Headlights are sealed, we are ready to put the rear rubber caps back on and do the wiring.


The rubber dust caps need to be slightly modified to fit the new hid bulb rubber seal.
Cut off this piece




Insert HID bulb into the dust cap, and secure the rubber seal




Fish the wires through the two holes and close the caps.


now put the plugs back on the wires, you will need to re extend the metal flaps on the plugs with a box cutter.

Last edited by borka; 09-12-2012 at 12:16 PM.
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Old 08-14-2012, 11:09 PM   #3 (permalink)
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optional demon eyes installation instructions:

To install the demon eyes, you need to open up the projectors and glue the demon eye rings.
You need to use high temp clear silicone to glue the demon eye ring, which is available on bkmoto or your local hardware store.

Here is the demon eye ring that needs to be glued into the projector.


undo the screws on the back of the projector body




undo the screws that hold the hi/low beam motor/flap




place the ring into the projector so you know where to put the silicone glue


remove the ring and put down silicone glue


Place the ring onto the silicone and let it dry for 12 hours.


Now put together the projector.





Wiring:

The wiring of this projector set is pretty simple
We will wire for both headlights to be on for low beams and high beams using the factory handlebar switch, with the addition of a small on/off switch which will enable you to turn off the headlights and keep the halos/demons on.

here is all the wiring labeled:

1. Connect both White low beam + to Low beam + pigtail
2. Connect both Blue high beam + to high beam + pigtail
3. Connect both Halo red + to low beam + pigtail
4. Connect both Halo black - to low beam ground - pigtail
5. all other connections self explanatory.

that's it.

Here is how to wire using a simple on/off switch to turn off low beam HID's to have only halo's on, or to start the bike with hid's off to avoid stressing the battery



Thats it, now put the bike together and enjoy your new lights!

Last edited by borka; 09-12-2012 at 12:17 PM.
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Old 08-14-2012, 11:10 PM   #4 (permalink)
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Old 08-14-2012, 11:32 PM   #5 (permalink)
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Bad ass! I was about to order this kit when I saw the thread pop up. Install looks pretty simple, just time consuming. I have a break coming up that I plan to use to install this kit in my bike. Looks like I'll be stopping at the auto parts store on the way home in the morning to see if they have that sealant tape you mentioned.
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Old 08-19-2012, 09:25 AM   #6 (permalink)
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My kit arrived yesterday, so I'm getting started on this shortly. I hope you finish the post by the time I'm done with mine, though my wiring will be different than yours due to my light being mounted to a different bike.

Kit arrived when he said it would and everything is in the box as pictured.
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Old 08-24-2012, 11:24 AM   #7 (permalink)
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This looks pretty sick... I may turn this into a winter project. Along with an exhaust kit.
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Old 08-24-2012, 11:37 AM   #8 (permalink)
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Quote:
Originally Posted by pburn883 View Post
This looks pretty sick... I may turn this into a winter project. Along with an exhaust kit.
Do it, the light output is awesome. I took about a day to install my kit. Getting the lens off was a bitch, but you just have to keep at it. After that the install goes fairly quickly. I resealed my light with a $4 tube of clear silicone from WalMart. The windshield ribbon borka spoke of was $22 for a roll much longer than I needed.
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Old 08-24-2012, 08:55 PM   #9 (permalink)
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For anyone wondering how the light looks.
Attached Thumbnails
HOW-TO: Install BKMOTO BiXenon HID projectors with angel eyes halos 2008+ Ninja 250R-imageuploadedbymotorcycle1345856093.851106.jpg   HOW-TO: Install BKMOTO BiXenon HID projectors with angel eyes halos 2008+ Ninja 250R-imageuploadedbymotorcycle1345856107.008061.jpg  
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Old 09-12-2012, 12:17 PM   #10 (permalink)
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The instructions are finished!
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