• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

TE630 HID conversion

I managed to find a cheap solution to my problem. I was looking for a similar size rubber boot from our local "Bunning" hardware store, and found this item (cost $2) in the plumbing section. I think they use it in the toilet area:

HID 004.jpg

I then fold it over:

HID 005.jpg

and tried it on the headlight assembly, and got a perfect fit:

HID 003.jpg

I need to butcher it a bit in order to fit the HID bulb assembly, and the apply silicon to make it waterproof:
HID 007.jpg
HID 008.jpg

I managed to push back the wiring loom behind the headlight assembly, and the whole thing fit! Not the best looking mod, but it is cheap and functional and you can't see the mess once installed. I now have to wait for the silicon to dry, and put some tapes around it to firm things up. I am looking forward to some bright light!
 
This is real overkill IMHO and creates more bulk behind the reflector.
If I recall correctly I merely cut the OEM rubber boot to the circular indent around the spade connectors - the HID rear fitting pushed through and butted up nice and tight (extra dab of silicone on edge if you want) and is water proof anyway. A snip of a cable tie or two and realignemnt of the harness and you are done. I had no issues and is working great after 1000km of all terrain use. Will see if I can get a pic of the setup later.
 
Thanks BIG DoM, Cutting the OEM rubber boot is a much better idea. Here is the picture:

HID 009.jpg

Got it fitted on to the bike. It puts out fantastic light, but is running quite hot. I am now a bit concern about melting the lens. I would recommend anyone considering the HID light conversion to go for the 35W version instead of the 55W.
 
just cut the rubber where the the terminals protude to a neat circle & fit it that way,i'll look at mine tomorrow & see if it will still seal,otherwise go to a local automotive wrecker & get a rubber seal that dosent have the terminal holes in it,we have fitted many kits in cars that way,& yes i know its not a car,that rear section that will hang out is normally fairly robust
 
A 55W HID should run significantly cooler than the OEM bulb that it replaces. It might be worth measuring stabilised reflector temperatures with the original halogen and the HID if it is a concern.
 
In theory, HID should run cooler, but the H4-3 bulb has a large metal shield covering the front and bottom of the bulb, so all the light (and heat) is concentrated in a small area directly behind and above, whereas the OEM bulb spreads over the entire reflector.

I had done a 55W HID conversion on my F800GS a year ago. Both reflectors has bits of silver coming off - but then it may be cause by the combination of drowning and high temperature.

I will stay with the 55W HID in the mean time, as it is a huge improvement over stock light.
 
Only weird thing about these reflectors is the angled pattern = typical fail of 'form follows function' with a design compromise!
 
BiG DoM said:
Unfortunately not.
Click to expand...

Trying to decide if it's worth going with the 35w HID.
I swapped in a brighter/whiter H4 bulb a while back, without pulling the headlight, so my harness is already zip-tied out of the way :p
Silverstar Ultra isn't all it's cracked up to be, btw...
 
RDTCU said:
Trying to decide if it's worth going with the 35w HID.
I swapped in a brighter/whiter H4 bulb a while back, without pulling the headlight, so my harness is already zip-tied out of the way :p
Silverstar Ultra isn't all it's cracked up to be, btw...
Click to expand...

The difference really is BIG
 
HUSKY 630 with 55w 6000k HID - CBR with 35w 8000k HID (both on high beam)2012-06-02_16-03-40_565.jpgHUSKY 630 from a different angle (not so blinding)2012-06-02_16-05-32_683 (2).jpgThis is the only before HID pic i could find, had to cut the picture out of a video of my brother taking it for a spin that i took with my phone so quality sucks 2012-05-11_15-02-35_469_01.jpg
 
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