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Day-time, parking lamp only426 viewsComparison of the two bulbs. On the left is the standard incandescent and on the right is the LED unit.
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426 viewsMounted and behind my Rizoma vented clutch cover.
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425 viewsI used a 5/8" socket to support the bearing so I could drive out the push rod.
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425 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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425 viewsInstalled and ready to ride!
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425 viewsAll the bearings are roller bearings and they are held in with the grease. When cleaning the grease and wiping the bearings they will most likely fall out so work over a soft, plush towel to keep them from bouncing away. Pack the bearings and cage surfaces with fresh grease and slip any fallen bearings back in. You should see no gaps between the bearings. Pack more grease in when they're all in and roll them around with your finger to spread the fresh grease around. It will hold them in there.
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...after.424 views
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424 viewsDue to the accessory plug on the left side the left bracket couldn't be a mirror image of the right side. I ultimately had to weld another piece of metal to bridge the original pieces, moving the resistor mounting plate further inboard and to the rear.
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424 viewsThe spade connectors snap in. If they are difficult to get out (at a later date, say, when replacing the bulb) you may want to use a thin, flat-bladed screwdriver to push the spade away from the female contact as shown.
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423 viewsFlap fully open, allowing some of the heated air to divert into the center of the Bus for the rear passengers.
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423 viewsNow the bar-end mount is up two inches at 34" high.
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423 viewsThe end result, push rod out.
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423 viewsPush the power supply wires into the original headlight bulb connector.
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422 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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422 viewsI originally tapped the existing mounting holes in the resistors with 4M x .7 threads but I decided to add Nyloc nuts to insure nothing came loose. All fasteners I used are stainless steel.
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422 viewsBefore, high-beam.
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Done!421 views
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421 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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421 viewsTo make it a little easier getting both of the HID wires into the small space I put a single loop in the wire, as shown. Then stuff it in there with the red wire.
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421 viewsInside of forward gear and planetary gear mating teeth.
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