HID Install without a fairing

[DGXSER]

I have had a really horrible issue with the stock headlight, especially on low beam being almost non existant. So I thought I would give the HID kit a try. I got the same kit Bug got. which BTW, only gives you one relay not two, so you can only install one bike, not two.

Anyway, for those who have installed this on a bike without a fairing, where have you shoved the components??

[ManagerMike]

Anyway, for those who have installed this on a bike without a fairing, where have you shoved the components??

Aww c'mon! you can't make it THAT easy

[DGXSER]

Aww c'mon! you can't make it THAT easy

Apparently, yes I can.

I been looking and thinking half the night. My current thought is to mount the ballast under the coils making a bracket that will hang it from the mounts for the plastic gas tank shield. Then put the relay part in one of two places, either in the empty spot behind the tip over switch, or take the box for the chain lock and cut it open in back and put the relay inside it. Only issue there is the wires that used to go into the back of the headlight need to run most of the way to the relay, so those become some long wires.

[XSive_speed]

How long is the high voltage wire on the HID box?

[DGXSER]

This is definitely a car setup. So that presents its own challenges. The wires from the ballast to the bulb are maybe 12-18" long. The wire to the battery from the relay is about the same length. The wires from the relay that go to the ballast are about 6' long. So the relay would need to be close to the battery, but can be a long distance form the ballast. The ballast needs to be close to the headlight bucket.

I toyed with the idea of mounting the ballast behind the headlight in front of the fork tube enough not to bind. But I would hate for it to come loose and keep the front end from turning when you need it to. So I scrapped that idea.

[Eveready1100]

This is where I mounted my ballast. It's one of the full sized ones, but it still fits comfortably in place with two zip ties.



Zip tied harness to frame tube under fuel tank.



I don't know if your kit's wiring is the same length as mine but it all fitted my Special perfectly. I trimmed off the unwanted second ballast feed wires from the harness just to tidy things up.

[ManagerMike]

Just an idea, the HID will render the RLU useless anyway. Ditch the RLU to free up some room for the ballast.

[MrOzz]

This is where I mounted my ballast. It's one of the full sized ones, but it still fits comfortably in place with two zip ties.



Zip tied harness to frame tube under fuel tank.

Same here.

Everything else fit in the head light bucket. Not that easily though.

[DGXSER]

Thanks for the concept guys!! That worked out for me also. Although the wire lengths did not allow all the connections to go in the headlight bucket. But I will wrap them in plastic wire wrap and electrical tape for added protection.

[MrOzz]

Thanks for the concept guys!! That worked out for me also. Although the wire lengths did not allow all the connections to go in the headlight bucket. But I will wrap them in plastic wire wrap and electrical tape for added protection.

You could use heat shrink to seal the connections. I did. Used the type that does not have the glue in it. That way when you have to open the connections you can carefully cut away the heat shrink.

[DGXSER]

OK, combined with the RLU elimination tip. This is one of the greatest mods yet!! The difference is incredible. Granted I had some issue somewhere in the lighting circuit it seemed as I could not see more than ten to twenty feet in front of the bike with the stock headlight set up on this bike. But even compared to my other SH, this is a serious improvement.

I got the 5k bulb as they were out of stock on the 3k. I was seriously impressed with this if you could not tell! Other than seeing the streetlight go by, you could never know by light level it was there!! You will not be out running the light on this thing without installing nitrous or something!!

[natemoen]

Get us some pics! I want to do this sometime soon so I want to see how you framed everything in the headlight bucket and how you ran the wires. Do you have a link for the seller?

[DGXSER]

Nate, the seller is the same one C-Bug bought from, only I got the 5k light instead fo the 3k (primarily because they were out of the 3k) So it is a whiter and maybe just a touch blue light.

I located the components the same place as Everready and Ozz. The raly come with two lengths of wiring connectors, one for a close bulb and one for a much longer one on opposite side of car. (it is a car kit). Use the shorter one.

I also took the headlight connector that was connected to the bulb and pushed it back out through the hole in the right back side of the headlight bucket. The wires that are part of the bulb go out the back of the bucket through the hole on the right side as well.

I'll get pics of the wiring tomorrow. I already have the tank and seat back on, and really, the photos Everready showed match mine almost 100%. Only difference is my ballast has a tab on one side with a hole. I used the wire tie to strap through that hole and around the bracket to hold the wire harness.

On the RLU, I figured no one needs those much if at all, so I cut off the wiring and connector form the RLU, twisted and soldered the two wires together from the first part of the RLU tech tip. Then I used wire wrap and e-tape to wrap up any exposed connectors and wires which all come together right next to the steering neck. Incidently, the second part of that tech tip on RLU removal seems to only apply to the Venturer, the high beam indicator on my bike lights up fine without that added wiring.

I already had a spare headlight so U used it. I did need to cut the rubber protector sleeve on the back of the bulb to get it over the HID bulb.

As to the wires inside the headlight bucket, well, that five pounds in a two pound bag became eight pounds in the same bag. I first took out all the wires and completely removed the bucket to see if the bulb and all would even fit. It does but with only 1/8" or less to spare. So you HAVE to get all the wires out from behind the bulb. From there it is squeeze push and rearrange wires until it goes back together. This is honestly one of the hardest parts of the entire job (after someone gives up the secret holes to hide the components like Ozz and Everready did.). The grounding wire to the ballast connection I took over the screw on the front of the voltage regulator.

From there, just enjoy the new and much improved light!!