Bi-Xenon Projector Removal For ZKW-R Lens

**brandonpham** · 11-10-2016 09:19 AM

Hey guys,

Midway through the black housing, CC and ZKW-R Lens mod. Wanted some input on how you guys remove the projector. I attached some photos. I was looking at the torx bolts in the back of the housing as shown in the photos. These are AFS. Do I remove these to get the projector and shroud out?

Also I wanted to get the trim around the turn signal out to paint it. I know Phil used a tried screw driver but is there any other option? Mine seems much more of a tighter fit than in his photos.

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**Audibot** · 11-10-2016 10:03 AM

You losing blinker fluid? I see that brown spot...

Seriously, though, curious on this too

**rongeur** · 11-10-2016 12:30 PM

Instead of removing the entire projector housing, I just removed the lens cage. It think there are 4 torx screws that hold the metal lens cage in place. Remove that and you can swap lenses and do any cut off shield mods you need.

**brandonpham** · 11-10-2016 01:47 PM

Originally Posted by rongeur

Instead of removing the entire projector housing, I just removed the lens cage. It think there are 4 torx screws that hold the metal lens cage in place. Remove that and you can swap lenses and do any cut off shield mods you need.

Is the 4 silver T25 torx you see in my photos?

**brandonpham** · 11-10-2016 01:50 PM

**rongeur** · 11-10-2016 05:14 PM

Dang, I am trying to remember since it has been 2 years or so since I have opened my lights, I though they were on the same side but I may be wrong. Try loosening it up and see if the cage loosens. I do remember trying to remove the entire projector and couldn't get it to come out completely so I just removed the lens cage instead.

IIRC, removing those silver torx will free the entire projector and from there you will get access on the other side for the lens holder screws.

**DanKing** · 11-10-2016 10:24 PM

Originally Posted by Audibot

You losing blinker fluid? I see that brown spot...

Seriously, though, curious on this too

Blinker fluid ?

What is that brown juice ?

**vvenom800tt** · 11-11-2016 08:01 AM

You have to remove the entire brown cage

**brandonpham** · 11-11-2016 09:12 AM

A bit of confusion here. The only screws visible are the ones from the back as shown in the first pictures, and the two to the right of the projector in the last picture. Not sure which ones to remove or begin removing. I'm assuming I should start at the ones int he back of the housing?

In addition, how has everyone removed the shroud for the turn signal? Did everyone actually get a shaved torx driver like Phil did? My shroud seems like a much tighter fit compared to his.

**Charles.waite** · 11-11-2016 10:32 AM

I used an allen key to get the torx screws out. Yea it didn't fit perfectly, but it fit well enough to get that extra fussy one snugged up.

**brandonpham** · 11-11-2016 10:42 AM

Originally Posted by Charles.waite

I used an allen key to get the torx screws out. Yea it didn't fit perfectly, but it fit well enough to get that extra fussy one snugged up.

So it is indeed the 4 torx keys I have circled?

**Charles.waite** · 11-11-2016 12:22 PM

I was referring to the clear corner torx, not the projector.

My only experience putting clear lenses in the projector was on my b6 but I know we just removed the whole projector through the backside of the headlight (since you can't easily remove the front plastic lens on a b6 headlight) and it was pretty simple.

**rongeur** · 11-11-2016 12:38 PM

Originally Posted by brandonpham

So it is indeed the 4 torx keys I have circled?

Yes, start with those screws and that should allow you to move the entire projector enough to access the lens cage screws on front side. I was never able to remove the entire projector for whatever reason but ended up not needing to swap the lens.

Fly300kts (Phil) used to have a very elaborate STI lense swap DIY that had some great pictures for reference since he actually chops up the lens cage to re calibrate the focal length since the STI is not a direct swap. I assume since he does sell them on the side, he removed the DIY due to hobby profit conflicts (my guess). Maybe he will drop in and shed some light since he is probably the most knowledgeable about these lights.

This was the thread: http://www.audizine.com/forum/showth...ictures-added)

Here is another thread with some of my insight back then (2013): http://www.audizine.com/forum/showth...-Xenon-Upgrade

**Ashtonts** · 11-11-2016 04:48 PM

Originally Posted by rongeur

Yes, start with those screws and that should allow you to move the entire projector enough to access the lens cage screws on front side. I was never able to remove the entire projector for whatever reason but ended up not needing to swap the lens.

Fly300kts (Phil) used to have a very elaborate STI lense swap DIY that had some great pictures for reference since he actually chops up the lens cage to re calibrate the focal length since the STI is not a direct swap. I assume since he does sell them on the side, he removed the DIY due to hobby profit conflicts (my guess). Maybe he will drop in and shed some light since he is probably the most knowledgeable about these lights.

This was the thread: http://www.audizine.com/forum/showth...ictures-added)

Here is another thread with some of my insight back then (2013): http://www.audizine.com/forum/showth...-Xenon-Upgrade

Are these the lens cage screws you're talking about? If so, how on earth did you get those out?? There's nowhere close to enough room to get them out with a regular t20 screwdriver

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**Axis** · 11-11-2016 05:16 PM

Originally Posted by Ashtonts

Are these the lens cage screws you're talking about? If so, how on earth did you get those out?? There's nowhere close to enough room to get them out with a regular t20 screwdriver

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You're supposed to remove the whole projector assembly. You then remove the chrome shroud of the projector from the rear (two tabs) and accessing these is now really easy.

Removing the projector assembly is 5 T20's. Disconnect the harness from the rear access trap first.

**brandonpham** · 11-11-2016 05:19 PM

Originally Posted by Axis

You're supposed to remove the whole projector assembly. You then remove the chrome shroud of the projector from the rear (two tabs) and accessing these is now really easy.

Removing the projector assembly is 5 T20's. Disconnect the harness from the rear access trap first.

Saw the harness and threads earlier thanks guys I will try again. I believe I had T25 but I'll double confirm.

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**Ashtonts** · 11-11-2016 05:21 PM

Originally Posted by Axis

You're supposed to remove the whole projector assembly. You then remove the chrome shroud of the projector from the rear (two tabs) and accessing these is now really easy.

Removing the projector assembly is 5 T20's. Disconnect the harness from the rear access trap first.

Are they on the front? I removed the 4 T20's in the pictures above already and I don't see any more back there to take out.

These ones? Or different screws?

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**Axis** · 11-11-2016 05:25 PM

Originally Posted by Ashtonts

Are they on the front? I removed the 4 T20's in the pictures above already and I don't see any more back there to take out.

These ones? Or different screws?

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Yes and you have two on the other side.

I'm saying that by memory. I've been taught to do it by an headlight guru.

**Ashtonts** · 11-11-2016 05:32 PM

Originally Posted by Axis

Yes and you have two on the other side.

I'm saying that by memory. I've been taught to do it by an headlight guru.

Then these two? I don't see how I could get these ones out either [banghead]

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**Axis** · 11-11-2016 05:38 PM

3 on the left, two on the right.

**Ashtonts** · 11-11-2016 05:49 PM

Originally Posted by Axis

3 on the left, two on the right.

Okay I had initially thought that those were the ones and I took em out, but I guess I just wasn't pulling hard enough, so I figured they weren't the right ones. Thanks though, got it out finally haha

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**Axis** · 11-11-2016 05:51 PM

Originally Posted by Ashtonts

Okay I had initially thought that those were the ones and I took em out, but I guess I just wasn't pulling hard enough, so I figured they weren't the right ones. Thanks though, got it out finally haha

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Push the bottom motor from the rear trap untill it pops out of its "track". Its a dimple in the bottom of the housing.

Once out, you'll have to remove the adjuster by pushing from the inside. (Push freaking hard) You'll understand once the projector is out.

**Ashtonts** · 11-11-2016 09:44 PM

Originally Posted by Axis

Push the bottom motor from the rear trap untill it pops out of its "track". Its a dimple in the bottom of the housing.

Once out, you'll have to remove the adjuster by pushing from the inside. (Push freaking hard) You'll understand once the projector is out.

Yeah that was a total bitch to get out. Got it all back together though and the other side should be a total breeze since I know what I'm doing. Maybe I'll even do a write up when I do the second one.

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**QuattriumMT6** · 11-11-2016 10:18 PM

Originally Posted by Ashtonts

Yeah that was a total bitch to get out. Got it all back together though and the other side should be a total breeze since I know what I'm doing. Maybe I'll even do a write up when I do the second one.

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Yes please document with photos!!

**fatkids** · 11-12-2016 06:44 AM

Originally Posted by Ashtonts

Yeah that was a total bitch to get out. Got it all back together though and the other side should be a total breeze since I know what I'm doing. Maybe I'll even do a write up when I do the second one.

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Please do as i want to do this mod in the spring time. :)

**Ashtonts** · 11-12-2016 02:08 PM

Originally Posted by QuattriumMT6

Yes please document with photos!!

Originally Posted by 706f7061

Please do as i want to do this mod in the spring time. :)

Will do! Can't promise exactly when I'm going to get around to it, super busy with class and work lately, but I'll definitely document the process when I do it, hopefully in the next week or so.

**a4darkness** · 11-12-2016 02:30 PM

No rush, thanks in advance. Really want to do the clear lens swap and would very much appreciate the documentation.

**QuattriumMT6** · 11-12-2016 10:47 PM

Can you take a comparison picture of the OE lens and the ZKW-R lens? I'm curious to see the difference in clarity. Supposedly out stock lens has a cataract finish.

**Ashtonts** · 11-12-2016 11:04 PM

Originally Posted by QuattriumMT6

Can you take a comparison picture of the OE lens and the ZKW-R lens? I'm curious to see the difference in clarity. Supposedly out stock lens has a cataract finish.

Already did. These are iPhone pics in bad lighting, but they show a decent comparison I feel. I'll try for some better pics on the next go around.

Stock:

ZKW-R:

Together (stock on bottom):

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**Charles.waite** · 11-12-2016 11:10 PM

Here's a direct comparison shot:

The OEM lens is cloudy.

**QuattriumMT6** · 11-13-2016 12:02 AM

How is the light directed with the ZKW lens without the cutoff?

**Ashtonts** · 11-13-2016 08:14 AM

Originally Posted by QuattriumMT6

How is the light directed with the ZKW lens without the cutoff?

The cutoff isn't in the lens, it's the edge of the high beam flap inside the housing. I'm assuming the line in the lens is there to blur the cutoff slightly to make it look less harsh, but at the expense of light output.

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**Charles.waite** · 11-13-2016 08:23 AM

Yea. It's there to diffuse the cutoff a bit I think.

**brandonpham** · 11-13-2016 11:54 AM

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**vvenom800tt** · 11-13-2016 12:33 PM

Would the cut off be sharper if we removed the "RV" flap that is riveted onto the highbeam flap motor?

**QuattriumMT6** · 11-13-2016 01:02 PM

Originally Posted by Ashtonts

The cutoff isn't in the lens, it's the edge of the high beam flap inside the housing. I'm assuming the line in the lens is there to blur the cutoff slightly to make it look less harsh, but at the expense of light output.

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Ohhhhhhh that clears things up. Aside from the clarity of the lens in the comparison pictures that was the biggest difference I noticed between the two.