m in sc wrote:
cut a new hole, use stock headlight grommet. reroute. easy. dremel time.
second, an RD can run a halogen just fine with a stock system, its not nec to run an led. 1 reason being is it screws up the taillight indicator on the dash if its still there. for those really concerned, you can get a 35 watt halogen that slips right in, the fzr's used to use them. beam seriously didnt look any different.
7" headlight IMHO looks crap on an rd, way too big. Like apretty girl with a huge beak hanging off her facehole.
My Daytona will run the battery down on hi-beam with the 55/60 halogen. I think the difference is the Daytona has two tail lamps verses one in the RD350. The RD alternator is maxed out in stock version and any increase in load needs to be offset by a decrease somewhere else, ie LED's in the tail and lamp.
Check continunity thru the brushes and rotor to be sure the field connections and brushes are good. Pull all the connectors apart, spray with a good electro cleaner and apply a good galvanic grease to the connectors as you put them back together. You may find some of the connectors fall apart when you do this. That would indicate the connectors need to be replaced by the way
After you go thru the electrical connectors reducing the voltage drops across the bad connectors you may will find the engine is stronger due to the increase of voltage availiabe to the coils. Adding more electrical load will tax the old connectors more so you need to be sure the connectors are 100%. I know Mark says the RD will run the 55/60 watt lamp but I have solved two owners electrical issues on their RD's by replacing 55/60 H4 lamps with 35/35's. If you have a good strong and healthy RD electrical system you may be ok but anything less than a 100% electrical system and you will have low voltage issues especially when you are running hi-beam.
Using a Led tail lamp in the RD350 will cause the brake light indicator to flash all the time due to the lower current draw of the led. The module is monitoring current draw and the lower current draw of the led tail lamp makes the module flash the indicator lamp. You can just unplug the tail lamp monitor module and disable that feature or unplug the indicator lamp inside the meter. For me I like running the led tail lamp to reduce the electrical load and disable the indicator lamp.
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I accidentally looked into it once at the Gap and had to stare at the sun for a while to rest my eyes! 
