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Blacked out 2006 600RR MiniH1 6.0

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  • Blacked out 2006 600RR MiniH1 6.0

    Ever since I got my bike Iíve wanted to retrofit the lights. The asymmetry of the low beam only being on one side annoyed my OCD side and I loved how a set of projectors could make the 600RR headlights look like a pair of angry eyes. While at university I never had the time and money to undertake the project to the standard I wanted but as a graduate it is a different story and this is a writeup of the process that I used while putting my engineering degree to good use.

    Despite there being kits available for the 600RR, I felt that I wanted to use a particular set of top end components for various reasons. I dislike the method of mounting a projector by a single point at the back of the bowl and felt that bolting it in would be more secure and eliminate the need to manually align the cutoff. I wanted to use LED halos as they are brighter and more durable while also not requiring inverters which would need to be hidden behind fairings. I also didnít want to add any aftermarket switches to my bike.

    Here is a before shot of the bike on the day I bought it.


    Parts that I used in my retrofit:
    - Morimoto MiniH1 6.0 projectors.
    - Mini Gatling Shrouds.
    - 5000K XB35 bulbs.
    - TRS dual H7 sportbike harness.
    - VW headlight relay P/N: 111-941-583.
    - Laser cut mounting brackets.
    - M4 nuts, bolts and bolts.
    The first thing I wanted to do was to flush mount the angel eyes in the projector shrouds. To do this, I enlarged the opening of the shroud to suit with a dremel and round file to tidy up.

    (Left is original, right is modified.)


    I then filed in a notch for the angel eye wiring and rubbed back, primed and sprayed the shrouds satin black.


    I used Blu Tack to hold the angel eyes in place before using epoxy to attach them to the shroud. It is important to use high temp epoxy so that the heat from the HID bulbs doesnít melt it.




    You can also see 4 places inside the shroud where I have dremelled a little material out. This is to make room for some bolt heads. I decided that I would replace the bolts that held the lens of the projector to the bowl with longer ones that could be used for attaching the projector to the mounting plate too. The heads of my replacement bolts were slightly larger than the original ones though which necessitated the grinding of the shrouds.


    In the quest for making the whole process as bolt together as possible, I spent quite a bit of time designing an aluminium mounting bracket which could be laser cut and powdercoated. I used black fasteners which have shown up gold in this photo.


    When I mounted everything up for a test fit I was disappointed to notice that I could still see the bolts attaching the projector to the bracket under the shroud. To fix this I got some PVC pipe and made up a ring to extend the shroud. This was then also painted.




    Test fitting now things looked much neater. I should note that I heatshrinked all of the wires black later on.




    You may have noticed in the second photo above that I have enlarged an opening between the headlight housings somewhat with my dremel. I also removed some material from the rear of the housing.
    Before:


    After:


    This gave me room to mount the fairly porky TRS ballasts in the space created. They are fairly snug just sitting there but I added Velcro tape to make sure they stayed put.


    The stock dust covers needed a small trim to allow them to work with the seal attached to the bulb wiring.


    The wires aren't yet wrapped up in this photo so it is easier to see what is what.


    I wired the angel eyes (red and white wires) into the stock parking light wiring.


    Since cutting stock harnesses makes me cringe I simply depinned the stock bulb connectors and used spade terminals and heatshrink to attach the aftermarket harness. I like to leave everything so that it can be easily reverted to stock should the need ever arise.


    As far as wiring on the bike, I ran the positive wire up through the rubber grommet into the fuse box which required a very minor lengthening of the wire.


    And threaded the negatives through the subframe alongside the battery negative wires.


    The harness then follows the factory routing.


    The relay block is safely tucked under the cluster using an OEM screw.


    And the bulk of the harness is zip tied to the fairing stay making sure to keep out of the way of the fork movement.


    Which leaves a nice neat finish.


    As I mentioned earlier I didnít want to add any aftermarket switches to the bike. Australian 600RRs have a momentary button on the handlebars for flashing the high beams.


    Since this is not a feature that Iíve ever needed to use, I decided that I would repurpose the button to control turning on and off the HIDs. This means that I am able to control the low beams as you would when driving a car. The halos are on all the time and being xBALED are plenty bright enough to be used as DRLs and the low beams only need to be turned on at night.

    To convert the momentary pulse from the pass switch into an on/off signal I bought a VW headlight relay P/N 111-941-583 which is a latching relay. Basically, when terminal S is given a ground pulse, a powered output is swapped between terminals 56a and 56b. By attaching the ballast trigger line to one of the outputs, the swap turns the system on or off. A possible variation here could be to attach the halos to the other output so that they turn off when the HIDs are on and vice versa.
    Last edited by Isaac; September 14th, 2017, 12:13 AM.

  • #2
    Unfortunately the pass switch is wired into the high beam circuit so OEM wires had to be cut here. I ran two new wires up the rubber conduit to the switch and soldered everything in. One wire went to the factory ground point on the side of the frame and one went to terminal S on the relay.


    Although the relay is bulky, it still fits nicely under the ram air tube cover.


    Iím extremely happy with the finished product. I think it looks mean.


    And Iím still amazed at just how bright the angel eyes are. (Not that my phone camera does much of a job of capturing it.)


    A few output shots.
    Low.


    High.


    Low.


    High.
    Last edited by Isaac; September 14th, 2017, 12:08 AM.

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    • #3
      Those headlights look AMAAAAAZING!

      It's crazy how small those are though (that the mini H1 doesn't fit without having a custom bracket)

      Also, just curious but might want to play with bulb seating on the left light (The cutoff seems to stop right at the step)

      Hers-Sloped TL's, ZKW-R lenses, 85122+, E55-R, fiberglass buckets, Blazer fogs with 3K
      Mine- Morimoto Mini H1's, e55 shrouds, Blazer fogs with 3000K
      Zuma 125 Mini H1, Gatling Gun 2.0, 90mm & 60mm Amber XBLED halos
      https://www.facebook.com/pages/RetroFix

      Comment


      • #4
        Originally posted by richterat83 View Post
        Those headlights look AMAAAAAZING!

        It's crazy how small those are though (that the mini H1 doesn't fit without having a custom bracket)

        Also, just curious but might want to play with bulb seating on the left light (The cutoff seems to stop right at the step)
        Thanks! The weird cutoff is due to the shape of the housing blocking the beam. Not much that can be done about it unfortunately. This was more of an aesthetic mod than a functional one anyway. I don't tend to hit up the twisties of a night haha!

        Comment


        • #5
          Oh i hear ya on not doing twisties at night! People fight back and forth with projectors on a bike, i love mine, but even with halogens, twisties at night is just not smart

          And Aesthetically, you nailed it! Props!!

          Hers-Sloped TL's, ZKW-R lenses, 85122+, E55-R, fiberglass buckets, Blazer fogs with 3K
          Mine- Morimoto Mini H1's, e55 shrouds, Blazer fogs with 3000K
          Zuma 125 Mini H1, Gatling Gun 2.0, 90mm & 60mm Amber XBLED halos
          https://www.facebook.com/pages/RetroFix

          Comment


          • #6
            Nicely done, looks good!

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            • #7
              Looks like you need to rotate the bulbs to fix the hotspots...

              Comment


              • #8
                good job on the build, i retrofitted my friends cbr for the exactly reasons, i hated that only one side light up and other was highbeam. i am to assume you live somewhere with RHD? where abouts?




                Originally posted by RSchmidt624 View Post
                Looks like you need to rotate the bulbs to fix the hotspots...
                hot spot is fine, the shape of the housing limits light output, as OP stated its for looks not functionality.
                Octa projectors, eight OEM bulbs, ~30,000lm , and 169 degrees of driving heaven!

                Comment


                • #9
                  Looks great OP. Just ordered a spare housing to retro my gsxr.

                  2000 Mustang Gt-SOLD RX350's Osram, Morimoto 5five ballast
                  2006 GSXR-G37 Projector,XbaLed halos,Morimoto 3five,Morimoto 4300k
                  2000 Ford Expedition-FX-R1.0s,Morimoto4300k,Morimoto 3five

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                  • #10
                    Originally posted by stockd15b View Post
                    Looks great OP. Just ordered a spare housing to retro my gsxr.
                    when you gonna be doing it? what setup you gonna run?
                    Octa projectors, eight OEM bulbs, ~30,000lm , and 169 degrees of driving heaven!

                    Comment


                    • #11
                      Damn I love the flush mount rings.

                      2000 Honda Accord SE -​Ruby Red Pearl
                      Morimoto MH1 5.0 5k 35W
                      Garnet-MR Thread

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                      • #12
                        yeah, they really do look killer, ive always used ccfl, but after seeing a few of these i want to give em a try.
                        Octa projectors, eight OEM bulbs, ~30,000lm , and 169 degrees of driving heaven!

                        Comment


                        • #13
                          Looks great. I think I am going to try to duplicate your lights. Where did you get your halos from and how big are they?

                          Comment


                          • #14
                            That really does look great ... well done.

                            It's interesting that the housing shape only affects the output on one side. What you could have done for the sake of symmetry is actually use a US sloped projector on that side. Of course the cutoff would have been bathtub shaped, but the output would have been better and the cutoff cleaner and less OCD panic attack inducing.

                            2015.5 RR V8SC
                            2015 Z06/07

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                            • #15
                              Originally posted by aeo 37 View Post
                              Looks great. I think I am going to try to duplicate your lights. Where did you get your halos from and how big are they?
                              They are TRS' own XB LED halos. They came as part of the complete kit I ordered but I believe they are 70 mm halos. Replicating these lights should be pretty easy, TRS now own the rights to the mounting bracket design that I created so if you email Matt at TRS he should be able to hook you up with a complete bolt in kit. Feel free to PM me if you have any questions that I can help you with.

                              Originally posted by soulsea View Post
                              That really does look great ... well done.

                              It's interesting that the housing shape only affects the output on one side. What you could have done for the sake of symmetry is actually use a US sloped projector on that side. Of course the cutoff would have been bathtub shaped, but the output would have been better and the cutoff cleaner and less OCD panic attack inducing.
                              I'm willing to put up with some slight OCD twinges for the sake of a safe and legal cutoff line haha! Thanks for the comments.

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