The install was done on my 06D which uses a single H4 bulb for both low/high beam. The kit I installed is low beam only as I very rarely used my high beam and the output is amazing, my color choice was 4500K as I wanted the most usuable pure white light. The kit is from Xenon Depot, www.xenondepot.com, they are willing to give forum memebers a 15% discount using promo code VROD at check out. If you have an A/B etc model the install will be similar with the obivous differences for headlamp housing etc but the basic steps and wiring are the same.
1. First unpack the kit, set everything out in a manor that you can locate all the parts, wires, relay etc. Its also important at this time to test the kit and make sure the bulb lights, DO NOT TOUCH THE BULB with your fingers, there are blue gloves (as seen in the pic) provided. Using a 12 Volt power supply (or bike battery if no power supply) connect the bulb to the ignitor then ignitor to the balast then to power along with relay, the bulb should light. If not re-check wiring and make sure relay is "clicking", I've never had a bad bulb but better to check then to get the install completed to find out the bulb is bad
2. Next remove the air box cover and make spot for the Ballast, I'm running topless so I used the bottom air of the airbox, you can use this location or choose somewhere else if you'd like, honestly its one of the best locations, close to the battery and headlamp assembly. Then go ahead and disconnect to the battery to prevent any issues.
3. Time to start removing the cowl/headlamp assembly. Pull the cowl forward to access the bolts. Then using a allen key(6mm I think) remove the 4 bolts that hold the cowl to the headlamp, use caution as the cowl will easily fall off at this point. Once the bolts are removed, take off the black plastic housing on the rear of the bucket along with the cowl and set them aside.
4. Using a allen key (6mm I think) and a socket(can't remember size, maybe 1/2" again metric/std can the Moco make a choice?) remove the bolt that at the bottom of the bucket, this attaches the bucket to the tripple tree.
5. Using a Phillips screwdriver remove the screw in the silver ring, this holds the glass lense in to the bucket, use caution as there is a small hex shapped nut on the back side of the screw that fits into the ring.
6. Pull the black rubber gasket off of the rear of the lense, this will expose the plug harness and the bulb/bulb mount. Pull the plug off of the bulb and then remove the bulb from the lense, there are 3 phillips screws that hold the metal bar onto the lense backing, remove them to allow the bar to be removed along with the bulb.
7. The lower screw also holds a metal bulb cap into the lense, this needs to be removed. Mine had a finger print on it from the factory that was rusting and would drive me nuts everytime I looked at the headlamp :chair:
7a. Metal bulb cap removed in my hand for clarification.
1. First unpack the kit, set everything out in a manor that you can locate all the parts, wires, relay etc. Its also important at this time to test the kit and make sure the bulb lights, DO NOT TOUCH THE BULB with your fingers, there are blue gloves (as seen in the pic) provided. Using a 12 Volt power supply (or bike battery if no power supply) connect the bulb to the ignitor then ignitor to the balast then to power along with relay, the bulb should light. If not re-check wiring and make sure relay is "clicking", I've never had a bad bulb but better to check then to get the install completed to find out the bulb is bad
2. Next remove the air box cover and make spot for the Ballast, I'm running topless so I used the bottom air of the airbox, you can use this location or choose somewhere else if you'd like, honestly its one of the best locations, close to the battery and headlamp assembly. Then go ahead and disconnect to the battery to prevent any issues.
3. Time to start removing the cowl/headlamp assembly. Pull the cowl forward to access the bolts. Then using a allen key(6mm I think) remove the 4 bolts that hold the cowl to the headlamp, use caution as the cowl will easily fall off at this point. Once the bolts are removed, take off the black plastic housing on the rear of the bucket along with the cowl and set them aside.
4. Using a allen key (6mm I think) and a socket(can't remember size, maybe 1/2" again metric/std can the Moco make a choice?) remove the bolt that at the bottom of the bucket, this attaches the bucket to the tripple tree.
5. Using a Phillips screwdriver remove the screw in the silver ring, this holds the glass lense in to the bucket, use caution as there is a small hex shapped nut on the back side of the screw that fits into the ring.
6. Pull the black rubber gasket off of the rear of the lense, this will expose the plug harness and the bulb/bulb mount. Pull the plug off of the bulb and then remove the bulb from the lense, there are 3 phillips screws that hold the metal bar onto the lense backing, remove them to allow the bar to be removed along with the bulb.
7. The lower screw also holds a metal bulb cap into the lense, this needs to be removed. Mine had a finger print on it from the factory that was rusting and would drive me nuts everytime I looked at the headlamp :chair:
7a. Metal bulb cap removed in my hand for clarification.