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Discussion Starter #1
Hey Guys,

I know a few of you have converted to LED headlights. I'm having a few issues doing this to my KLR. I've got a 2011 with the H7 bulbs. I ordered a set of LED replacements for the same from SOCALMOTOGEAR (I think they're pathfinder LED's). These have the fan on back vs. the braided heat sinks. Problem is, they will not fit into the housing. More specifically, the screws that hold the retainer clip are in the way and won't allow the bulb to seat into the housing. Also, the retainer clip itself doesn't quite look like it will bend enough to lock the bulb in place even if I clear the screws. It's the fan that is catching on the retainer screws. Is there a brand out there that is plug and play? Or is there a kit available for the KLR? Kind of has me bummed. Finally get my plate cleared of all of life's BS and some decent weather to boot only to find that these aren't going to work. Thanks in advance.
Bill
 

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Cyclops Adventure Sports has a kit. I put my kit in the year they became available for the Gen2. Been quite happy with them. Looks as though the current kit puts out even more light than the original kit. The only thing I really had to do was adjust alignment, down, once I installed the lights. Installation which was easy, assuming you remove the fairing to change bulbs.

KLR GEN 2/Versys/Ninja/Goldwing LED Headlight Bulb Kit
 

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Discussion Starter #3
Thanks for the info. I just looked these up. They're double the lumens of the pathfinders that I have so these things should really light up the night. Thanks again.
 

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I don't know what your bulbs look like, but I have installed several different LED H7 and HID H7 bulbs in my gen2 KLRs with little trouble. Notice that Kawasaki used a little plastic stand-off about 1/4" thick between the spring and the stock incandescent bulb #23017 here 2011 Kawasaki KLR650 (KL650EBF) Headlight(s) | CyclePartsNation Kawasaki Parts Nation

I cut a piece of 3/4" PVC pipe the same length as the stock stand-off with a flat spot and a tang to match the flat and tang on the stock stand-off. This allowed the spring clip to work as originally designed without any bending.


I final quit trying to use LED and HIV bulbs in the KLR reflector housing which they were not designed for. Never could get any of them to focus well due to incompatibility of bulb and reflector. The light went everywhere.
 

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Discussion Starter #5
Thanks GoMotor,
I think I'm going to order the Cyclops lights at RMATV. These seem (at least according to some reviews and tjduexjr) to work pretty good in the KLR. I had thought about doing just what you did, putting a spacer in to raise the back of the fan up enough to be able to lock the spring clip in place. I decided against that as for two reasons. First, as near as I could tell, I was probably in the neighbor hood of around 5/16" from seating the bulb (give or take a little). Second, with the bulb set back that far, what kind of light pattern would I get (possibly something as you described). The cooling fan (as near as I can determine from pictures) seems to have a sharper angle on the cooling fan housing and maybe a bit longer shaft from the bulb to the housing. If so, this should eliminate my problem of the fan housing bottoming against the two screws/tabs that hold the spring clip. Hope so anyway. Thanks just the same for the input.
 

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Thanks GoMotor,
................ with the bulb set back that far, what kind of light pattern would I get (possibly something as you described). The cooling fan (as near as I can determine from pictures) seems to have a sharper angle on the cooling fan housing and maybe a bit longer shaft from the bulb to the housing. ............................
Yes, the flange with a flat edge and a small tab on the back of the bulb has to sit flush with the back of the reflector housing or it will not focus. I put the spacer on the back of the bulb flange, but the bulbs I was using had a longer neck between the fan and the bulb leaving room for the spacer and the spring clip.
 

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I put LED lights in my 08 from RMADV. They have been great!

Cyclops-Adventure-Sports-LED-Headlight-Bulb-H4-3800-Lumen

They have been great! I removed the stock retainers and built new ones out of stainless safety wire. I also had to modify the rubber boot to fit the fan the lights had on the back. I put an o-ring on each bulb to keep the fan from hitting the housing and to seal the light housing from dust/water. I have not had any issues with them since installing them just over a year ago. They are SUPER bright. If I ever want to go back to stock, I will have to buy new dust boots.






 

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Discussion Starter #8
That's what I'm expecting to do. Nice job, especially the pictures! I'm expecting to get the new bulbs in by the end of the week. It's nice to see that the fans actually fit inside screws for the retaining clips. That's where mine are hitting thus, not allowing me to seat the bulb. Glad to hear that they are BRIGHT too. That's what I'm looking for. Thanks for sending all the pics. Shows me exactly what I need to do.
 

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That's what I'm expecting to do. Nice job, especially the pictures! I'm expecting to get the new bulbs in by the end of the week. It's nice to see that the fans actually fit inside screws for the retaining clips. That's where mine are hitting thus, not allowing me to seat the bulb. Glad to hear that they are BRIGHT too. That's what I'm looking for. Thanks for sending all the pics. Shows me exactly what I need to do.
The o-rings are critical to getting everything to seal and line up. You can see the placement in the 2nd photo if you blow it up. It was kinda a pain keeping it in place until it was seated. Also make sure you are using safety wire as it is very strong and will hold it's shape under the screws. Good luck and let us know how it works out.

Sent from my SM-G930V using Tapatalk
 

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Discussion Starter #10
BTW, do you remember what size O-rings? No biggie if you don't, the local hardware store has all sorts.
 

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I don't. They were in a Harbor Freight set (Storehouse®*-*Item#67554). $8 for 382 o-rings is a pretty good deal! They need to be snug around the base of the light. Had to stretch them just a bit in the install.

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Since size, shape and location of the element compared to the H7 incandescent element seem to effect the focus of the light, I wonder how the offset caused by the big O-ring affects the focus of the light from the LED.
 

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Since size, shape and location of the element compared to the H7 incandescent element seem to effect the focus of the light, I wonder how the offset caused by the big O-ring affects the focus of the light from the LED.
The only difference I have noticed is it is much brighter with the edges being more defined. I think the high beam pattern may be wider as well. I haven't really noticed people flashing brights at me any more than before.

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