I had my stock bulb burn out, and wanted to replace them with LED lights. I ordered these:
H7 LED Headlight Conversion Kit
Supposedly these are directly compatible. However, I ran into a lot of issues. The connector is too fat to fit in the housing all the way, the electronics that come with the bulb inline with the wiring in a small metal box doesn't fit inside the housing, and the bulb is too deep to accept the housing cover. I read online where some people just leave the covers off, even in rain and dirt, but I didn't feel comfortable doing that.
The first thing I did was measure the housing cover and make a CAD model of it. I added 9mm to the depth and 3d printed it. After a few trials, I got it to fit right.
Here is a picture of my first trial:
As you can see, the connector and electronics didn't fit in the gaps well enough to allow the cover to be installed.
So I started really going crazy on it and extended the wires so I would have enough room to work, and replaced the connector with a smaller one, and chopped the electronics housing. This is how my left headlamp was done. On the right headlamp, I learned from the first and figured out I didn't need to replace the stock connector or the new headlamp connector... as long as I had enough wire, I could manage to get the connector shoved into the headlamp housing. I didn still need to lengthen wires and chop the housing. What follows are some pics of my setup.
Above is a picture of my mod, before covering with electrical tape
Above image shows mod covered with electrical tape.
Above pic shows what I did to make the electronics fit. I very carefully cut the housing with a dremel cutoff wheel (blew up about 2 or 3 wheels per housing). The PC board is glued into the housing, so I did not want to risk breaking it trying to pry it off.
Above picture shows how I fished the components into the headlamp housing. It's all pretty tricky and takes some patience. Even installing the bulb is not trivial, because the wire latch tends to get caught up on the fins of the heatsink, and all of it is in a hard to access area.
Above picture shows both home 3d printed housings (made on an Ultimaker 3), installed. The housings clear the forks when I turn the handlebars side to side. If I had made them any deeper, that would have been an issue.
Above is a housing I had "professionally" printed using Shapeways.com
The project if you attempt to do this yourself would cost $100 for the bulbs and $70 for the housing covers.
I am super happy with the results. Before the mod, I had lousy yellowish lights that were useless on lowbeam, and ok on high beam. I relied primarily on all my auxilliary lights. Now I can see very clearly on low beam, and it's a very nice white light.
If you want to attempt this project, you can buy the 9mm deeper housings at my Shapeways store:
Purchase Super Tenere extended headlamp housing cover
You will need to buy 2 covers and reuse your original o-ring. I have a 2013 Super Tenere, and assume it would work on all models, but am not sure about that. Also, if you can find a different brand of LED bulb that doesn't have the issues with fitting electronics inside the headlamp housing, but just need a deeper cover, this could work for you.
Good luck
