Katana Owners Club U.K.

Could not find a guide and members are asking about the ease of fitting a MR2 headlight unit.

I bought 2 crystal MR2 headlight units, have heard mk1 units fit (mine should be).

And here is hopefully an easy step by step guide.

This is how the front view looked like before swap. To gain access to light you must remove fairing which is held on by 5 screws/bolts, gently remove side panels by pulling outwards which then reveals the rear fixings, then remove 2 more fixings underneath lower front of fairing and last fixing situated just behind screen area. then pull fairing forwards to remove from bike revieling headlight and frame. Now the fairing is removed you can see the headlight is secured by a metal frame secured by 2 small phillips screws at bottom, mine were rusty so wire brushed threads but 1 i had to cut a slot into it to remove, once screws are out pull frame out from bottom. Then lift frame upwards off the 2 top lugs, my light then stayed in situ. I then seperated the headlight bulb plug and pulled out the side light bulb, take care not to drop the light unit.
The unit is now free and i placed beside Crystal unit for comparison.

The only difference i could see was the four raised seating points on the back were slightly deeper than on the original metal unit. I then measured with a vernier gauge the original thickness of mounting to compare against new unit. As can be seen the new crystal unit is wider. I then scribed all four mounting points. After this i held the new light unit up against the headlight frame in its final position.

Will add the rest tommorow!!!!!!!!!!!!!!!!

will you be drilling a hole for the side light bulb? Or does it have one already?

bobster wrote:will you be drilling a hole for the side light bulb? Or does it have one already?

All will be revealed in part 2 Bobster

This has got all the hallmarks of an article for "The Pride"

For the benefit of the non-forum members of the club, obviously.

Looking good

As is Johnr's petrol tank rust removal technique using a cement mixer

Pete

Carrying on from yesterday

Whilst holding the lens in situ i took a pencil and marked thru from the back, giving me 4 clearance marks on the seating lugs. I then placed the Old unit and new unit lens down to mark the location for the side light bulb (in this i have allready removed the rubber grommit. You will now see i have 4 pencil markings on the seating lugs and a + for the hole for side light gromit. I then got out my hacksaw, and proceed to cut off the excess material from the seating lugs. After cutting off excess i filed down all 4 areas's to form a smoother seating point.
Pictures shows only 1 corner but you get the idea

I then got out my drill (cordless or electric) and proceeded to drill a 3mm pilot hole, which i then used a 13mm drill (exact hole size in original unit) to open up hole for rubber grommit.
*Have heard sidelight bulb is not required but i wanted to keep it*
Next i blew out all the swarf with my airline. I now had a complete modified unit, to which i installed the sidelight bulb grommit (fairy liquid applied) and then installed a brighter uprated headlamp bulb, then fitted the rubber boot (note the slot or hole goes to the bottom for drainage) Now having a complete ready to fit light unit i did exactly that, firstly push fit the sidelight bulb into grommit then locate headlamp unit and push on main headlamp wiring plug. Now the unit was back in its frame i got hold off the light retaing frame, and proceeded to slip it over the 2 top securing lugs and then push lower part over bottom off light. Then picking up the 2 screws i proceeded to tighten them up with my screwdriver.

Now light was secured into frame i checked to make sure all lights worked After that i then refitted the fairing and TA DA All done.
As can be seen its a lot cleaner and brighter looking.
But i can not say how crisper and brighter light i have achieved as yet to test it in the Dark
If i get time i'll try get pictures tonite to show difference Now please Note this was all based on believing i had Mk1 MR2 light units, but not having seen Mk2 units i can not say what the difference is

If you think or know off an easier way off doing said modification please comment and i will ammend post