FZ6R - How to install HID Headlights

[MikeN02]

Some people like me, had trouble finding a full write up on how to install these darn things. So I'm just doing a little write up, not a whole lot of pictures because i didn't have my camera on me but I took some of what I could.

Prep Work, Before you begin.
Tools and items you'll need is the same as my other thread:
-Hex Key, Allen Key
-Socket Wrench (for the seat, and headlight).
-Philips Head (4 Way Screw driver)
-Gloves (So you don't get your natural oily skin on the bulb)
-Containers (for screws, trust me on this one... I had a few extra)
-Drinks/Food

Step 1: removal
As mentioned by JonKerr of this forum:

Originally Posted by JonKerr

First thing to do is pull ALL the plastic off the bike. Fairings, fake ram air intakes, mirrors, inner fairing covers, everything. When you go to take the front fairing off, you can just unbolt the 4 main bolts holding the headlight assembly onto the bike. You don't have to take the fairing off the headlight unless you want to. After you unplug the headlight from the main plug, and can take the assembly to a work bench

So, basically you take all of the fairings off. If you haven't done frame sliders yet, here's my frame slider thread: FZ6R - How to install NO Cut Frame Sliders

After you remove both side panels, you remove the air intake plastics. When you remove the side fairing, you'll see 4 or 5 screws that require a 4-way or Philips Head screw driver. Unscrew these and then take off the air scoop plastic.



Looks like this:


After you take off the sides, you now want to start working on the dash. Take off the dash side plastics:



This is taken off by a hex key bolt and a plastic quick screw, then slide the plastic off.

The dash is next, held on by the same thing. A quick screw and a hex key bolt:



After that, slide the dash out and over the gauges and set it aside.

The mirrors are easy to remove, as they're only held on by 2 nuts for each mirror. Unscrew these and the mirror will come right out, I used my socket wrench for this, just have to move the handlebars to get some room.

Next, you'll be on the ground looking up at the bike to see what's underneath. You should see a plug going in to the bulb to connect it to the power, as that's the only wire connecting to the headlight unit. Just pull that sucker out like a wall cord because that's basically what it is.



The only thing you have left on there is the headlight. DON"T unscrew the philips head screws in the headlight display, it's a waste of time. If you look there's 4 bolts that hold the headlight unit in place. They're bolted on to a silver/metal frame bracket. You're gonna want to stick your socket wrench in there and unscrew those bolts.



After that gently pull the head unit off and take it to a bench or table and work on it there.
The bulb itself is covered in a rubber rain/weather protector. I used the two little stubs that stuck out and pulled it off. After you get that big thing off you'll see a little metal/paper clip spring that holds the bulb in place. Push down on the right side of the spring and unhook it, then pull it to the left. Take the bulb out.



Step 2: Installing it

With rubber gloves on so you don't touch the bulb. Take off the plastic cylinder case of the HID bulb. And put in the headlight like the stock bulb, also, it might be a little tough but you can put the spring over it again to lock it in place instead of unscrewing the spring and screwing it back in. For the weather rubber protector, I just stuck it over the new bulb and electrical tape the hole so no water gets in.

If you're unsure about how the ballasts connect, look at the wires with the instructions and they should clip together. Unlike the stock bulb where the 3 prong wall cord connects directly to the bulb, the bike's connector will connect to the ballast instead.

Now you're going to want to think of where you're going to mount the ballast, making sure that it doesn't interfere with the steering. Some members say you can just use one, but I used two since mine came with two and I think if you only used one you'll just get the low beam. I mounted mine on the front with the double stick tape that came with:


And the other side here:


Move your steering left and right to see if it hits it or interferes with it, if it does then you're in trouble.

You're going to have to run the 2 Positive and Negative wires through the body, using zip ties/cable ties to hide it there and to the battery.

Now put the head unit back on and screw in the 4 bolts. Connect everything together, and test out your work.

Step 3: Putting everything back together

Go reverse order when you put everything back together, starting from the dash first and the side fairings last.

Here's where I cable tied the wires in the front:

[99vengeur]

Your photobucket ID is FantasyKnight!

Seriously though, nice write-up. I hope this helps all the people who had questions. So the ballasts just plug right up with the stock wiring? There was not cutting or splicing?

[MikeN02]

Originally Posted by 99vengeur

Your photobucket ID is FantasyKnight!

Seriously though, nice write-up. I hope this helps all the people who had questions. So the ballasts just plug right up with the stock wiring? There was not cutting or splicing?

Yeah, was a final fantasy fan and made it as a teenager lol.

The ballasts do plug right into the wiring, the bike's plug is like a wall jack, and the ballast has the 3 prongs that just stick right into it.

[rubicon1000]

how about some pics of the bulb in the stock location please

[MikeN02]

I'll try and get some pictures but as I mentioned I didn't have a camera at the time. Plus I start work again for the weekend.

[Kleinfalls]

Originally Posted by MikeN02

Yeah, was a final fantasy fan and made it as a teenager lol.

The ballasts do plug right into the wiring, the bike's plug is like a wall jack, and the ballast has the 3 prongs that just stick right into it.

Why do you have to run power back to the battery if the ballasts plug in to the factory wiring? More than single 12V power required? Where did you purchase yours from?

[MikeN02]

Originally Posted by Kleinfalls

Why do you have to run power back to the battery if the ballasts plug in to the factory wiring? More than single 12V power required? Where did you purchase yours from?

The ballast does plug into the factory wiring (three prong outlet like a household electrical outlet, it's just that you have another set of wires (red and black, positive and negative) that need to connect directly to the battery or so.

I'm not entirely sure why though, if someone knows the mechanics of HID lights they might be able to explain to you more about it. I just followed the instructions.

I purchased mine at the same location as everyone elses, DDM tuning. I got the 35W 6,000 single Hi/Low beam for $45 about 2 weeks ago and now it's on sale for $35 I believe.

Also an Update: JonKerr was right, the double sided tape they supplied you with sucks. Mine fell off on the right ballast, the left ballast I had it trapped with a little hook on the frame. I think it might have been when I was riding in the rain also. Have to find another way to glue or stick it on.

Overall I still like this mod, the light is really good and bright at 6,000. My friend even commented how great it looks and he saw it in the daytime.

[Diluted]

Would something like industrial strength velcro work? I'm using it on my pedal board for the guitar and the pedals are stuck pretty well even only having 1/3 of the pedal covered.

It's relatively cheap too, can get like 5ft or so at Michaels for around $10

[JonKerr]

Good industrial strength velcro would probably be just fine. As long as the adhesive side will stick to the painted frame. That seems to be the issue. Not much likes to stick to that. The Shoe Goo I used works perfectly and if I ever need to remove it, it's just a matter of getting a flat blade screwdriver under the edge and it'll pop right off. Then the goo will just peal off leaving no residue.

One update on my HID, some of you may remember I posted that my bulb had an odd yellowish green tint when I installed it. I finally got annoyed enough to send DDM an Email about it. When I was doing the install, the buld did slip out of my grip and I caught it by the bulb. I wiped it off with a lint free cloth but apparently, the damage was done. That's why when you look at the bulb, part of it has the nice white/blue tint and where my hand touched it it turned yellow. The same is true when it's on. Looking at the headlight at certain angles, the light looks the right color. But head on it's yellow. Lesson learned, when they say don't touch the bulb, they mean it. I'll be getting a new system tomorrow. It's only $5 more to buy a whole new kit than it is to buy just the bulb. I figured I'd just spend the extra $5 and have back up ballasts and wiring if some freak accident happens. One of their offices I just found out today is about 4 blocks from where I work. So I'll stop in tomorrow and get it and put the new bulb in this week.

[Diluted]

Jon, is your kit the one with a single ballast or the dual ballast like Mikes? I'm not as broke as I thought I was so I think I'll be ordering this.