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583 viewsNotice that the ballast (flat, squarish box) is going in first and the ignitor (long rectangular box) is still outside.
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581 viewsAll apart and ready to go! The headlight fairing is two pieces.
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578 viewsHere's the plug to be modified. I found it unnecessary to remove ALL of the plugs per the instructions but you can. Remember to lift the red tab up to unlock the connector.
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576 viewsMeasure the length needed to be wrapped, add 1/2" to 1" extra, and cut with ordinary scissors. The wrap I used was 16" and it worked well to wrap the circumference of the duct with a little over-lap. Put the over-lap seam down so if water should get in, it will drain out. I had 11" and 8" zip-ties so I used them together to hold the wrap. Snug it down until it just dimples the insulation; don't reef down on it and over-tighten it!
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576 viewsThe mirror end assembly. Tightening the Allen bolt pulls the nut in, compressing the rubber sleeve and expanding it outward, providing a tight interference fit inside the handle bar.
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573 views
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573 viewsNext, use a small screwdriver to lift the inner plug out. It only moves a few millimeters so you don't need to completely remove it!
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573 viewsUsing needle-nosed pliers remove the tits from inside the plug backing for the #16 and #11 holes. Don't remove the others as they fill the holes in the seal.
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572 viewsLot's of neglect to repair :-(
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572 viewsRemove the puny OEM bulb. Carefully put it aside and don't touch the glass. You may want to save it as a spare, just in case.
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571 viewsClose up of mounting the VR to the back of the gauge body.
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571 viewsAfter, low-beam.
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570 viewsNew grip installed.
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570 viewsAfter.
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569 viewsLooking forward at the center section. I clipped off the stock duct zip-ties, wrapped the duct, and then zip-tied the duct back to the mounting points.
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567 viewsThe 3-pin connector apart. Next up is the 2-pin connector. After that the headlight can come completely off the bike. This is done by pushing the assembly up in the same direction as the fork tubes until the bracket comes off the upper pegs. Pull it forward a little to clear the pegs then downward (if a Strada windshield is in the way) and forward to clear the bike.
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565 viewsAll wired up, fog harness plugged in & grounded, and the fuse box ready to be re-installed. I used a stock grounding point under the module per the Routan instructions. The Chrysler instructions show the ground attached to the negative battery cable.
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565 viewsMounting points.
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565 viewsBefore, low-beam.
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564 viewsFog wiring harness, right side, zip-tie location.
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