KTM 640 Adv illumination

Discussion in 'Thumpers' started by PASSMORE, Jan 19, 2005.

  1. timeOday

    timeOday Long timer

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    This looks great, I might have to copy you.

    With the big hole for the mesh to come out, won't it get awfully dusty inside there? LEDs last so long maybe it would be OK to seal it up with gasket maker.
  2. scrminbanshee

    scrminbanshee Ready to travel

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    I did think about that and i am curious to see how it will last. I was thinking about getting some big heat shrink and getting it as small as i could without it really touching. The thing to keep in mind tho is that if i can get 3-4years out of a bulb then ill just replace as they blow out. i wish you could a cyclops in the low beam side as the fan i feel would do a better job of keeping the bulb cooler but ultimately ill just see how it goes.
  3. docwyte

    docwyte Long timer

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    I just did the low beam as I have a set of Aux lights I use with the high beam. No issues with dust in the low beam lamp and I've been running it awhile...
    tbrown-bc likes this.
  4. Droptarotter

    Droptarotter Long timer

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    My solution..........Hella 60mm HID/Baja Designs Squadron Pro high beam...........both lights on when high beam activated.......my world is now illuminated!!


    IMG_1503.jpg
    DistortedAxis likes this.
  5. mtbdemon

    mtbdemon Long timer

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    That is SWEET!! I may have to message you on this....
  6. Droptarotter

    Droptarotter Long timer

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    Yeah, no problem......include your email and I'll send some lousy photos of how I built the mount for the lights.......have been meaning to do a new thread but life has gotten in the way.

    Cheers
  7. gunnerbuck

    gunnerbuck Island Hopper

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    [​IMG]
    These are similar to the bulbs I installed in both headlights... They have there own reflectors so I tossed the oem low beam reflector.. On these bulbs they screw apart in the middle similar to a nut and bolt... I made the backing plate out of thin steel, drill the correct size hole in the middle, thread the bulb in place and then screw and bond the plate onto the front half of the headlight housing.. I prefer the single large button Cree LEDs, they seem to hold up the longest...

    I have a side by side cree bicycle light with these button leds and it is unbelievably bright for its size, I am going to retrofit it to a gopro mount base and then I can install one on my helmet visor and one on the 640s windscreen and then I can move the light around... The nice thing is it has an 8 volt lithium ion battery pack but will also run on the 12-15 volts that most motorcycles put out... It also has a weatherproof plug that separates it from the battery and plugs directly into my heated jacket outlet on the 640.. For side lights I run the triple 5 watt led lights you see on Ebay, they hold up very well if you install a lexan shield in front of them and drill lens drains... I have a 3" pair of 10 watt single Cree bulb lights I am going to try on my last project bike and see how they work, I'll try to get some pictures up of the installation..
    hajoktejnSI likes this.
  8. scrminbanshee

    scrminbanshee Ready to travel

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    Pm sent that is a sweet set up!
  9. Droptarotter

    Droptarotter Long timer

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  10. BrokenHalo

    BrokenHalo Squid Racer

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    In an attempt to reduce the draw from the halogen lights and improve the lighting I contacted ADVMonster and got some LED H-1 replacement bulbs. I was thinking these would be plug and play and I was wrong. So, I went to grinding & cutting on the housing to accommodate the new bulb. Finally get it all fitted and put back on...No way I'll be able to make right hand turns (fine for NASCAR but not adventure riding).

    Now after reading this thread it looks like some have had success with the mesh type bulb. Unfortunately, I did not get the mesh type. Has anyone found a solution for the non-mesh style bulbs?

    Here is what I got - CLICK HERE
  11. BrokenHalo

    BrokenHalo Squid Racer

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  12. meat popsicle

    meat popsicle Ignostic

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    I'd be disappointed to buy a bulb labeled "H1" and find its not actually an H1. But you're problem now is the low beam bulb is worse than stock? Lighting specialists (like Daniel Stern) say that shoving different bulbs into housings is a bad idea (and illegal in the US) because they're not made for each other, and won't project properly. I'd return the bulbs and consider getting a replacement housing with an LED. Many do what you've done, but YMMV of course.

    EDIT: here's a link from earlier in the thread:

    http://hamsar.com/products/forward-lighting/headlights/

    EDIT: new model of 90mm capsules with both hi & low in one:

    https://hamsar.com/new-90mm-bi-led-highlow-beam-headlight/

    LED capsules - look like they might be direct replacements for the 640adv but for the price you better make sure and check the lumens/output.
  13. BrokenHalo

    BrokenHalo Squid Racer

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    I did get an "H1" bulb. It just seems there are variations of it?
    ADV Monster is willing to take the bulbs back allowing me to get the "other H1" bulb.

    I get what you saying about replacing the entire set up. I think for maximum benefit that is the way to go for sure. Especially if price is not a factor.
  14. dnrobertson

    dnrobertson Big Bike, Slow Rider

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    It appears to me the problem with LED monster bulb is:
    1. The huge heat sink on the base (rear) of the bulb
    2. The length of the bulb assembly (due to 1).

    I have seen some LED replacement bulbs with a mesh heat sink. This may work better. But another vendor on adv of LED bulbs refuses to sell any bulb that does not have a fan to cool it.

    I have been more than happy with my el cheapo Chinese HID. Over 4 years and 30,000 km on mine. About 2 years ago I added a Rigid Industries LED light bar under the main lights. The light bar is now my main high beam and with various switches I can:

    1. HID low beam (with excellent beam cut off and no blinding of on-coming vehicles).
    2. HID low beam and LED light Bar High beam. (this solves problem of HID warm up when switching).
    3. HID low beam, LED light Bar High beam and HID High beam.

    When I did this, I replaced the tail light with a LED as well. So with 2 x HID and LED, I'm not using much more power than the 2 standard halogen bulbs.
  15. BrokenHalo

    BrokenHalo Squid Racer

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    Update: I originally contacted ADVMonster and was recommended to use these H1 bulbs. Even though these bulbs are listed as H1 bulbs after grinding & cutting on the housing they will not work with the the 640 due to the large heat sink. The heat sink would hit against the fork tube. I contacted ADV Monster and he said send them back and I could get the mesh style and a credit for the others. So, I ordered the mesh style and then shipped the first pair back, pending a refund. I got the mesh ones and after modifying the cover on both hi/lo I was able to get the mesh bulbs to work. Unfortunately, I misunderstood the credit and only got a prorated credit. I'm sure there's some fine print somewhere about being prorated, even though the bike never came off the stand with them installed. For the prorated amount & shipping I prolly would have been better off to try to sell them - Lesson learned.

    So, if you are looking at replacement headlight bulbs get the mesh style and be prepared to cut a hole in the back of the housing to fit the bulb.

    I still need a taillight bulb. May give Cyclops a call for that.
    hajoktejnSI likes this.
  16. Hipster

    Hipster Long timer

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    I have the Adv Monster Mesh H1 low beam bulb installed in my bike and I've checked the mesh many times and it's never been hot. Also, I formed the mesh so it doesn't touch the fork tubes.
  17. Droptarotter

    Droptarotter Long timer

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