Hello! I have blue a 2001 FZS600 and made the projector mod to it during this winter.
I originally posted this on Modified Fazers Facebook Group (as a short version) and I was asked if I could do a write-up to here FOC-UK site. So here I am, all registered user and doing the write-up for you.
I didn't take much photos during this operation, so I just try to explain what did I do. There are some photos but not enough to cover everything with photos.
As we know, the FZS600 original halogen reflectors are bad, really bad. At first I did the usual, modded the H4 low beam wiring and after that I put the HID bulbs on stock reflectors. Okay, the HID system on stock reflectors were massive improvement on light amount and made possible to drive through night on dark roads. But the glare (light everywhere) and hotspots weren't good at all so I begin to search projectors. First I spotted the official Retrofitsource FZS600 projectors -kit but the price was too high for me. So the hunt for cheaper projectors begun. Some searching and reading several reviews later I found a chinese two 2,5" projector kit from Aliexpress mere 30€ price!
http://www.aliexpress.com/item/Car-Styling-LHD-RHD-2-5-inches-Mini-WST-HID-Bi-xenon-Headlight-Projector-Lens-H1/32290777652.html?spm=2114.10010108.1000013.1.MfbxDoI personally have really good experience of those chinese "el cheapo" stuff so I ordered them. Only thing I worried was of course the quality and the real size of the projectors, will they fit inside the headlight housing. Well, the projectors were 5/5 for the quality (metal reflector bowl housing, a glass lens and so on).
It was time to start modding.
First step was to separate the headlight housing and removing the old reflectors. I put the whole headlight unit in the oven approx. 3-4 minutes in about 150 degrees Celsius. After heating I pried the front lens off with flathead screwdriver. Then I screwed the reflectors off and gave the whole unit a good cleaning.
Then it was a lot of measuring, testing and wondering how to fit those projectors inside and maintain the adjusting ability. And I have to say, bigger projectors than those just simply won't fit.
First I decided to cut the original reflector and mount the projector on to it. After the first cuts and testing it became clear that the original reflector as a bracket wouldn't work - the projectors were just too long for that. I decided to make my own brackets - similar type than those of the "official" retrofit kit contains.
I made the brackets out of a 6mm polycarbonate. I measured and marked the alignment attachment points, cutted the polycarbonate to right size pieces, drilled a hole middle of them (the projectors go partially through the brackets) and glued the original adjustment points to it.
I wanted a dark look to the headlight so I painted all parts matte black, the DIY brackets, spacers and the shrouds. Painted plastic primer first and then the matte black heat resistant paint on top.
I also wanted to replace the stock parking light bulb with something else and came up with the idea of LED light strips inside the projectors. I installed strips of white LED inside the projector shrouds, around the projector itself, so the LED light would kind of glow through the lenses.
Then I assembled the projectors on to the brackets with some 20-30mm spacers (can't remember the actual lenght). Installed the LED strips around the projectors and finally the shrouds on top of it.
Next was to install those completed "units" to the headlight housing. Simply by twisting the adjustment screws and popping the one "snap points" .
After the projectors were installed into the headlight unit, I took the LED strip parking light wires and projector high beam solenoid wires and routed them to come out back of the headlight. After that I baked the front lens back to the housing by putting it on and heating it again in a 150C oven for a 3-4 mins. Then I pushed the headlight back together. After it was cooled I put some aluminium tape around the seam, just to make sure that dust and water won't get in.
And now the wiring. Because I wanted good power delivery for the HID ballasts and ignitors I decided to install relays to feed the power. So both HID's get their power directly from battery via own thicker wires with fuses and relays.
The wiring goes from battery + terminal and left side of the bike (near the steel frame tube) all the way to the front, behind the instrument panel where the two relays are. Fuses are near battery, behind the black plastic cover where there is bike's own relays and such.
Those HID relays behind the instrument panel are controlled with the original H1 wiring and the original H4 wiring is used to control the high beam (projectors high beam solenoid). Those parking light LED strips got their power and earth connection from original parking light wiring.
So the bikes original wiring controls those only those less power needed things, LED parking lights, high beam solenoids and relay solenoids. The high power feed comes directly to the ballasts its own path via relays and thicker wires.
Then I installed new 5000K bulbs into the projectors, put the rubber covers back and took the LED parking light and high beam solenoid wires through those rubber covers. I use the 5000K HID bulbs because they give the pure white light and almost most light output. More light, the better I say.
I installed the HID ballasts and ignitors inside the front fairing on to the sides with "heavy duty" double sided tape, one each side. Time will tell will the tape hold....
Next step was to install the headlight back onto the bike, connect everything, tidy all wires with zip ties and so on. I tested the system and it worked great! I did the beam alignment so everything would be correctly set.
I haven't really tested this on the road yet but I'll plan to start season 2016 in next week. Then we'll see how this works in real situations.
The light output is something awesome, it's even, wide and sharp! I can't wait to get to drive in dark with these!
Feel free to ask any questions.
I've uploaded the photos into my Drive folder. The link:
https://drive.google.com/folderview?id=0ByzOWUi2pfRYVVc5alBQSlVSWEk&usp=sharing 
