06-08 Headlight and Hood on an 04/05

Installation Guide

Parts Needed:

- 1 x HEADLIGHT UNIT - 33110-HP1-600 **

- 1 x HOOD - 61350-HP1-600ZA

- 2 x BOLT & WASHER (6X25) - 93404-06025-08

- 1 x STAY, R. HEADLIGHT (Right Silver Bracket) - 61105-HP1-600

- 1 x STAY, L. HEADLIGHT (Left Silver Bracket) - 61106-HP1-600

- 2 x Stainless Self Tapping Bolts (Picture)

- 2 x Rivets and Backup Plates (Picture)

** If buying a headlight assembly from someone make sure to have them send the following parts. They won’t be needed by the original owner after taking off the light.

- 2 x Rubber grommets and collars on left and right side of headlight.
- 1 x Silver center bracket attached to headlight by single bolt and grommet.

Instructions:

1.) For ease of installation, remove both front fenders and shrouds.

2.) Remove both black fender brackets and total of 4 bolts. (Picture) (Black brackets are no longer needed.)

3.) After removing brackets, reinstall the 2 rear-most bolts to frame/radiator mount. (Picture)

4.) Unhook rubber splash guard from old headlight support tabs. (Picture)

5.) Cut off headlight supports as they will be in the way of the new lights mounting location. (Picture) (Make sure to leave just enough of the tabs to reinstall the splash guard.) (Picture)

6.) Install new silver headlight brackets using the 2 remaining bolts from the original black fender brackets. (Picture) (Do not tighten these bolts all the way down just yet.)

7.) Install new headlight using the 2 new bolts and washers. (Make sure to run the bulb wires above the bottom bracket. Wait to connect the wiring until just before installing the hood, so that it stays out of the way.) (Picture)

8.) Reinstall fenders and shrouds. (Picture)

9.) Now center the new light within the shrouds and tighten down the left and right bracket bolts. (Picture)

10.) Once the light is centered and brackets tightened down. Install self-tapping bolts. Driving them into the front cross member of the frame between the 2 existing holes. (Picture)

11.) When installing the new hood the rear-most posts and tabs should fit perfectly.

12.) The third tabs should be slightly out of place and requires you to slot the front shroud to allow for this tab to have a place to sit. (Picture) (Take your time and create a slot that is JUST big enough for the tab to fit into. You want it to fit tightly.) (Picture)

13.) Front most tabs do not have a place to mount. This problem can be solved by riveting the hood to the shroud. (Using a backing plate on the rivet helps support the plastic of the hood since there is a minimal amount to rivet through.) (Picture) (Either buying black rivets or painting/coloring them prior to install helps them look more natural.)

Parts you should be left with when complete.

*** Thanks to Matt (MSTRAV) for engineering this install and working out the bugs on his own quad first! Not to mention helping me install my own! ***

excellent writeup Gumby... Now, did you notice a difference in brightness or anything or was it about the same? I'll get this put somewhere, just let me find where, so we can catalog it with other guides.

I haven't ridden at night yet. But I like the light pattern it throws much better.

I added it to my Online Reference thread. But anywhere else you think it should be.

http://www.trx450r.org/forum/index.php?showtopic=29267

I'll just pin it here. Good enough to stay at the top, surely there are other peeps wanting to do this.

Just thought I would throw up some pictures from todays Pismo ride since it shows the headlight.

Greg.... I know I copied your avatar photo, SO SUE ME!!!

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I just realize I need a new helmet, the blue and black just isn't working out anymore!

Good info Gumby

glad to see that Duncan Bumper on there that i sold ya. looks nice it just wasnt my style. dunno why i even bought it

wow gumby, looks alot better imo!!!

great write up and the quad is looking nice, but gives me some deja vu with gregs 450r like u said




-lumi

I don't see it on "Parts Needed" section in this topic but I must buy also 2k6 hood yes? what is number of this part?

yes you need the hood. find someone on this sight selling the light and get the hood from them as well.

Thanks for pointing that out. I went ahead and added that part number above. (61350-HP1-600ZA)

You're a good guy gumby! Your "online reference material" came in very handy! Thanks!

Hey thanks for the post. This is something that is going to help me a great deal. I have just purchased a set of OEM white plastics for my 04, and my installation process has come to an abrupt halt. It appears that I'm going to need to install the 06-07 lights on my 04, plus get a new hood. And no, this is not a direct bolt on process to those who want to buy the OEM white plastics for their 04-05 model. There are some modifications that must be done to make things fit. Changing the light assembly and hood is just one.

if you could takes pics and show what "mods" you have to do to the plastics. I alreeady have the hood and light on mine now i want white plastics on my kicker. at least take and post pics of things to look out for

matt

Id be interested in hearing about or seeing some of the mods required as well.

hey what all would i need to do to just put the hood on, i run mx and i dont want the lights, but also dont want to drop the $$$ for a good looking hood when i can pick up an 06/07 for cheap...

The hood couple rivet, rivet backing plates, rivet gun and a utility knife is all. Just follow the last few step of installing the hood.

Only thing is your probably gonna be left with a pretty exposed view of what is under your hood and where the light was. Might not be very pretty. Most after market hoods are longer than stock so that they at least partially cover what the light did.

on the 05 hood theres a plastic the covers the underneath of the headlight. will it still work on the 06light? or does it get eliminated?

You'll have no need for it.

first thing awesome write up.....that almost step by step what i did with my conversion......


curious tho if anyone has tried the front fenders from a 06-07 on a 04-05??? all bolts line up? cause if so....you wouldnt have to do any plastic cutting and no rivets.....everything would just "pop" together....



if anyone has let me know.....if not....i might be purchasing them to see.....and ill do a write up on the outcome.....

Yes, the 06/07 front fenders will bolt up with no modifications. I recently put an 07 headlight, front fenders and hood on my 05.
Also, if you buy Maier front fenders they have the slots for both the 04/05 and 06/07 hoods.

My 05 with 07 plastics and light

sweet.....good to know....ill order them this week.....


also i noticed the color code for black with the 06 07 is metallic ????


anyone noticed a color difference with the 04 05 black to the 06 07 black??



thanks

I actually never even thought about replacing the front plastics along with the headlight. Good to know they bolt up properly. I may do that one of these days.

I was able to stuff the 07 headlight under a maier vented hood on my 05. Looks really freaking good. The headlight is almost unseen and provides plenty of light for night rides. I will try to post a picture tomorrow I dont have any of it at the moment.

does any kind of mod need to be done using the newer style headlight and aftermarket hood? can't find an answer anywhere, maier says the headlight has to be removed but have seen several people keep it on the 06+ bikes, thanks

It depends on the hood. Some hoods are made to dip down lower for taking off the headlight entirely. But most of the hood companies have stock replacement hoods that don't dip so low so that you can keep the headlight. Anyone of those styles that allow you to keep the light should work just fine.

^^^^^exactly^^^^^

Here is my Fourwerx Motorsports Hood. 100% Carbon Fiber.

Hey just wanted to say this is some good info. I just put the headlight and hood on mine. I done mine alil differently than shown. Instead of trimming where the tab on the 06-08 hood hits the fender tab.

I cut the slotted piece off of the fender on each side.

Then marked where to hook shaped tab on front of the new hood is on the fender.

Took my soldering iron and melted the slotted pieces I cut off down toward the front of the fender where they would meet up with the new hood.

This worked out great and didnt need to use any pop rivets at all.

Didnt take any pics of the process but I will have finished pics of it tommorrow if ne one is interested.

I just did the mod on my quad and cut little slits in the plastics up front to slip the tabs into similar with what is stock on the 06/07 but without have to buy the newer plastics.

Ill post pics later

Did you ever post the pics ?