DRZ Headlight Brackets
Version 2.0 - New and improved!
The new version drops the headlight assembly 5mm lower to improve visual appearance and help close the gap between the headlight and the front fender. The front support now has a better looking triangular design and is thinner reducing the amount of material used, also saving on printing time and cost.
Here are some brackets to convert your DRZ to a KLX headlight
Remove your old square headlight, leave that square mount inside and bolt up the new brackets, it will need longer bolts. *With the updated 2.0 version zipties are no longer needed for additional support* I did have to use 2 zip ties on the side to help secure it down since the windscreen that was added needed more support.
The aftermarket version of the KLX headlight has 2 extra side support mounts. The version on the bike is an OEM KLX headlight shroud, it does not have those extra mounts. That design feature can be added in if someone sends me the dimensions.
- An DRZ Auxito LED bulb, drops right into the KLX headlight (its a little crooked but it works)
- Printed with PETG and Nylon, PETG should work just fine.
- Mirror the side mount for the left and right brackets.
Included is the front support mount for added support for the windscreen, the bike has an afr gauge but a different version can be made without the hole for the gauge. Lmk
Will include the solidworks files on Thingiverse to modify for your own needs.
Version 2.0 Improvements
The new version features significant improvements in both form and function. The design has been optimized to be more aesthetically pleasing while increasing structural integrity. The refined dimensions and enhanced material efficiency make this version a substantial upgrade from its predecessor.
- Lowered mounting position for better aesthetics
- Improved triangular support design
- Reduced material usage and print time
Version 1.0 - The Original Design
These brackets are compatible with all DRZ400 models from 2000-2024, ensuring a wide range of applications. The design has been tested to ensure increased stability and proper fitment across all model years.
The project started with detailed sketches and 3D modeling to explore different mounting solutions. Considered various factors including aesthetics, structural integrity, and ease of installation.
- Sketches, measurements and CAD modeling
- Multiple design iterations
- Optimization for 3D printing
First Prototype
The first version established the core concept and functionality. While overly complicated in design, it successfully addressed the need for a reliable headlight mounting solution. This version taught valuable lessons about requirements and preferences that influenced the later improvements.
Early prototypes were crucial in identifying potential issues and opportunities for improvement. Each version brought closer to the final design, with valuable insights gained from hands-on testing and feedback.
- Original proven design concept
- Basic but functional mounting system
- Field-tested durability
Project Origins
The idea for these brackets emerged from the DRZ community's need for a better headlight solution. After seeing numerous riders struggle with makeshift solutions with mounting the KLX headlight, decided to create a purpose-built option that would combine reliability, repeatablity and aesthetic appeal.
Download the Files
Get the 3D printing files for the DRZ Headlight Brackets on Thingiverse.
DOWNLOAD THE FILES HERE