Installing Ken’s Factory NEO-FUSION Headlight

Ken's Factory Neo-Fusion Headlight

Ken’s Factory Neo-Fusion Headlight

Sportster LED Headlight Install

Hank Thibodeau of Widowmaker Custom Design and Repair installed a Ken’s Factory NEO-FUSION Headlight on a 2007 Sportster. The install requires standard hand tools and a little bit of soldiering.

The headlight bucket from Ken’s Factory USA is so stylish that it looks like motorcycle jewelry. Ken Nagai is the renowned international motorcycle designer that builds high quality and premium components.

Ken's Factory Neo-Fusion Headlight

Installing LED headlamp into Ken’s Factory Neo-Fusion Headlight

Hank decided to upgrade the Neo-Fusion bucket with a Rivera Primo LED headlight with built-in turn signals. This keeps the motorcycle old school but with upgraded with cutting-edge tech.

The Rivera Primo LED headlight is a very tight installation. Only time will tell if vibration reduces longevity.

The First Order of Business – In order to unplug the wiring harness from the wiring loom you will need to remove the gas tank, seat and plastic housing. Then place your new bucket and soldering equipment on your bench.

Ken's Factory Neo-Fusion Headlight

Plug in connectors

Before you get started on soldering, plug the headlamp into the stock connector. Then assemble the headlight and bucket.

Ken's Factory Neo-Fusion Headlight

Stripe the wires

Now strip the wires from the headlight and the wiring loom.

Ken's Factory Neo-Fusion Headlight

Twist the wires

Butt the wires up against each other and gentle twirl them in opposite directions to ensure good connectivity.

Ken's Factory Neo-Fusion Headlight

Soldier the wires

Heat the wires so that the soldier flows in between the copper strands.

Be sure that you add the shrink tube on before you begin soldering. If you don’t you’ll start over again. Shrink tubing is heated on the exposed wires to keep moister out of the connection.

Ken's Factory Neo-Fusion Headlight

Loctite the bolt

Add a dab of Loctite to the bolt that secures the headlight.

Ken's Factory Neo-Fusion Headlight

Tighten the bolt

Then bolt the bucket to the bike.

Then plug in the connectors and put the wires back in their hangers on the bike. Install the gas tank and attach the seat. Start the bike on and check your work.

Sportster LED Headlight Install & Testing


WIDOWMAKER CDR – Hank Thibodeau – Hank ha designed and constructed numerous award-winning motorcycles for a variety of clients including choppers and modifying existing bikes to full ground-up construction builds. Hank has been a professional mechanic for nearly 20 years. He started out as a master diesel technician for 8 years prior to opening his own shop in Rougemont North Carolina.

HEADLIGHT – The Neo-Fusion headlight is a substantial unit fabricated from aluminum billet with a black or brass-plated ring. It has a look of jewelry. Mount block comes with mounting screw pitch 3/8” UNC and is offered in6 different combinations of color and material.

HEADLAMP – The Rivera Primo 5-3/4″ Phase2 HedLED Headlamp is a slick upgrade that features a super-bright Cree Xlamp XM-L LEDs that will outshine almost any halogen or H.I.D. headlamp. They feature integral amber LED turn signal/running lights built into the headlamp shell. It’s currently on closeout at J&P Cycles and the customer is waiting for a killer deal in order to have one in reserve.

Ken's Factory Neo-Fusion Headlight

2007 Sportster Engine Update

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