KTM 950 990 Adventure LED headlight version two

thingiverse

Modified the original! Now with a 5 degree tilt-up on the highbeam (to reduce hotspotting and get a increased throw for offroading after dusk), removal of the not-needed lower support brace, and more surface area for better retaining the lower led. **After temperature testing, the BajaDesigns leds will get hotter than the glass transition temperature of PLA and PETG. They'll thermally throttle to around 80C but the housing can heatsoak to 90-95C with a duration of 30 minutes. Print this in ABS or annealed HTPLA at minimum** To offset the throttling I designed two sets of fan/filter brackets. Brackets (A) puts the fan in the top hole. There may be clearance issues during aiming that I'm still resolving so I made a combo bracket (B) which puts the fan in the lower hole. Both power cables route through the lower hole for both brackets. I'm using a piece of cloth mesh (from the ktm's prefilter no less) to act as a filter, it's washable and waterproof. a standard 50mm fan is glued to the bracket found here: [amazon fans](https://www.amazon.com/gp/product/B01MTA09QV/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1) These are printed in PLA currently, 1mm wall, 20% fill. From the original: An alternative to the European headlight mod or drop in LED bulbs for the 9x0. This bracket retains the use of the factory adjuster mechanisms and utilize Bajadesigns squadron LEDs. You'll need to reuse the nylon pivots and steel adjuster bracket from the original incandescent housing. The Clear lens will come off if you bake the housing at 130C/265F for 7-10 minutes to soften the adhesives. ***This has not been certified for legality. Modify your ride at your own risk!*** [more details on assembly here](http://mju.io/led-headlight-retrofit/)