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Old 09-27-2008, 08:03 PM   #316
SinCityJets
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A piece of that big plug IS REMOVABLE. It will still be a little too big to fit through the hole, but you will have to just notch a little piece of each side. Just enough to fit the little tab sticking out on both sides.

I just put the "removable" part back on once it was through the grommet.

JUST DON'T TOUCH THE BARE LIGHT BULB!!
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Old 09-27-2008, 08:16 PM   #317
nostatic
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Quote:
Originally Posted by SinCityJets
A piece of that big plug IS REMOVABLE. It will still be a little too big to fit through the hole, but you will have to just notch a little piece of each side. Just enough to fit the little tab sticking out on both sides.

I just put the "removable" part back on once it was through the grommet.

JUST DON'T TOUCH THE BARE LIGHT BULB!!
is it too late if I licked the bulb?

How much of the body work did you pull? Looks like I should remove the beak which if I understand correctly requires both side panels to be pulled. I already figured out that the aluminum panel with 3 screws doesn't need to come off. I thought that it was mounted at least with one of the screws to something other than the side panel below. Silly me...

edit: notched the dust cover with a drill and got it through. The rubber grommet looks like it might fill the gap, but I'll likely shoot a bit of rtv in the trough to make sure it is waterproof.
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nostatic screwed with this post 09-27-2008 at 09:55 PM
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Old 09-27-2008, 10:48 PM   #318
SinCityJets
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I don't know what bike you're putting it on, but all I removed was the windshield and the instrument cluster. I mounted my ballasts under the beak (tank guard brace). There is no room on the adventure to mount them under the body panels like JVB did :(
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Old 09-27-2008, 11:21 PM   #319
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Quote:
Originally Posted by nostatic
it's always something...

So I get a 24mm hole drilled per the instructions, go to thread the harness through and it turns out that the main plug is actually about 28mm wide. There are two tabs for a wire retainer and needless to say, 28mm don't go into 24mm (though there might be a porn plot there).

Anyone had this issue?
Yes. I just pushed the pins out of the connector with a small square nail from a nail gun. There's a little tab on each pin of the connector you can push in to release the pin and it will come out of the connector. Feed the wires through the hole you made in the housing cap and just remember which pin goes back in each hole when you re-insert.
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Old 09-28-2008, 01:14 AM   #320
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Bluhduh I'm Having a Hard time...

Has anyone had trouble re-installing the metal things that hold the bulbs in place? For some reason I have had a hell of a hard time screwing them in. I don't know if my hands are too big to reach in but I can't seem to get the bulbs to stay put against the reflector, for some reason they are not tight enough.
Anyone's had the same issue?

thanks,
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Old 09-28-2008, 05:32 PM   #321
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Happy to report that the install is complete and it works fine so far. It was a pita figuring out where to stuff things and how they could be attached. I have the thin ballast which has a separate ignitor. While the smaller size is nice, you then have 2 "things" to mount. I ended up doing 4 zip ties - one on the igniter and 3 on the ballast, going to the front support above the oil line on the right side (did low only). The igniter tucks underneath the ballast (towards the outside). Took me awhile to put the pieces together. Would have been easy to plop the igniter on the front horizontal support but the harness for the speedo runs there and I figured I didn't want to put any voodoo voltage near that harness. Not that I'm paranoid or anything...





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Old 09-28-2008, 08:39 PM   #322
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Done

Another successful HID conversion completed.
I got kit with the little larger ballasts with integrated igniters, and like many I too discovered the GS offers precious little space to cleanly mount the ballasts.
Most other have been able to somehow tuck two ballast inside/under the beak plastics, I could device sturdy mounts to make that work all that good. Others have mounted the ballast directly under the oil cooler, that seem a bad location to mount any "made in China" electronics.

So I came up with yet another place for the two ballasts. Directly on top of the head light housing. To mount them I casted a "base" out of black epoxy resin (long process...).
The base in "glued" down to the head light housing with some clear exterior grade silicon caulk and ballasts stick to the base with double-sided foam tape.
The wiring between ballasts and the bulbs becomes also pretty clean this way.

Couple photos from along the way, starting with the end result:













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Old 09-28-2008, 09:39 PM   #323
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Very nice!

Jim
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Old 09-28-2008, 11:09 PM   #324
SinCityJets
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FF,

What are the chances of getting one of those black plastic doo-hickeys from you?
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Old 09-28-2008, 11:25 PM   #325
FlyingFinn
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Quote:
Originally Posted by SinCityJets
FF,

What are the chances of getting one of those black plastic doo-hickeys from you?
Chances are very good.
I have the mold and plenty of epoxy left to make more casts. I'm on a work trip all this coming week but I could cast one or two more next weekend (it takes 24h for the epoxy to harden).
I'll send you a PM when I have one I can sell.

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Old 09-28-2008, 11:35 PM   #326
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Question

Okay, so I finally was able to attach the metal retainers by removing the headlight. Wish I would've done it sooner, it just took me a few minutes!

What I am wondering about is my HID kit, I bought it off e-bay from China, as many of the inmates. My question is if you guys' bulb fit all the way into the light housing all the way like stock does, plastic base included. Mine doesn't, it doesn't seem to seat all the way in, or at least in uniformly, thus leaving some room for movement if you play with it a little bit.
Is this normal? Any thoughts?

thanks.
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Old 09-28-2008, 11:54 PM   #327
FlyingFinn
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You need to get the bulb seat properly.
Mine were little snug too, it took bit of effort the get them all the way in there but after a while even the more stubborn one did snap in place.
The instrument cluster comes off really easy if you need better access to get your fingers in there...

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Old 09-29-2008, 07:03 AM   #328
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Quote:
Originally Posted by FlyingFinn
So I came up with yet another place for the two ballasts. Directly on top of the head light housing. To mount them I casted a "base" out of black epoxy resin (long process...).
The base in "glued" down to the head light housing with some clear exterior grade silicon caulk and ballasts stick to the base with double-sided foam tape.
The wiring between ballasts and the bulbs becomes also pretty clean this way.
Mikko
I've mounted mine similarly but much less hi-tech, I bolted the two mounting plates together to hold the two ballasts end to end with the wires on the outside ends, wrapped them (top and sides) with a thin (2mm) rubber material and zip tied them to the screen mount bar just above the headlight. The wiring is very clean as you say and nothing is glued to anything.

I've checked for heat after an hours riding with the lights on and the ballasts don't even get warm (vvme hids). Been there a couple of months now with no problems.
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Old 09-29-2008, 07:59 PM   #329
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At some point in this thread I believe there was a discussion about the HID bulb length vs halogen. I have not been thrilled with the light I have been getting from the HID's so I got me to thinking. I pulled the HID bulb out and found that the HID "filament" was .050+ further into the reflector than the halogen bulb. I made a shim and it made all the difference in the world. The light went from a very focused rectangle to being slightly less focused with a lot more light up close making it more usable in my opinion.
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Old 09-29-2008, 08:38 PM   #330
SinCityJets
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Quote:
Originally Posted by bodybomber
At some point in this thread I believe there was a discussion about the HID bulb length vs halogen. I have not been thrilled with the light I have been getting from the HID's so I got me to thinking. I pulled the HID bulb out and found that the HID "filament" was .050+ further into the reflector than the halogen bulb. I made a shim and it made all the difference in the world. The light went from a very focused rectangle to being slightly less focused with a lot more light up close making it more usable in my opinion.

.050 what? Inches, millimeters, centimeters?
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P3 LED Tail Lights www.p3lights.com
HID Low Beam / High Beam / Fog Lights www.vvme.com
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