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514 viewsGrasp the original bulb to gently pull the reflector straight out. I show this angled so the inside end can be seen. Gently push the bulb in just a little bit and then rotate it to remove it. Mine were in there quite snug! The LED unit goes in the same way as the bulb. Put everything back together. Done!
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513 viewsConnect the wires to the power plug. Now all the ignitor and ballast wires are attached so you can push them further into and down inside the headlight bucket. Now you can loop in the other zip-tie to secure the ballast, cutting notches in the hourglass brace like I did if you want. If you removed the high-beam bulb you can now put it back in, along with its wires.
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511 viewsHere's what the left bracket looks like. Ugly. But it works, keeping it away from plastics and wires, so that's what matters in the end.
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510 viewsRemoving the spacer.
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Done!508 views
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...after.507 views
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507 viewsUnscrew the bolts and remove the spring caps and springs. The pressure plate then pulls straight out and the push rod comes with it.
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507 viewsFirst zip-tie installed. I waited on the second one so I could move the ballast a little while working on the electrical cabling. This just helps get the ballast out of the way and keeps it from moving around too much. You can now install the HID bulb and secure it.
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507 viewsConnect the ignitor wires to the bulb. One thing I did to make this wiring install easier is to remove the weather seal that holds the 4 wires. Since everything is contained within the headlight bucket there's no need for the wiring seal. Carefully use a sharp blade, like a crescent X-acto blade, to cut the seal and remove the wiring.
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506 viewsNow the bar-end mount is up two inches at 34" high.
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505 views
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505 viewsMy fingers are pointing to the two pins that fit into the two rubber grommets that are part of the upper triple tree (visible in the foreground).
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505 viewsDetail of the bottom of the unbolted ladder.
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505 viewsI used my engine hoist to lift my bike by the frame. I'm so glad I have this! This was necessary to get the full extension sag measurement as well as lifting the bike to take pressure off the lower bolt so it could be removed.
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505 viewsPush in the power supply spade connectors into the headlight connector. As can be seen in the picture, I put the black wires together and the red wire with the white wire.
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505 viewsPush the power supply wires into the original headlight bulb connector.
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504 viewsFor safety I wrapped each connector in electrical tape and then wrapped them together as well.
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503 viewsUse a drift to tap out the push rod.
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503 viewsThe end result, push rod out.
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503 viewsHere's how the clutch basket looked. Those streaks are LOTS of thread locker applied at the factory. It leaked out the back side as well. After removing the eight retaining bolts I had to use a drift and tap a couple of the ears on the basket to gently break it free.
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