Zoinks!
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I finally got the HID kit installed in the bike. Can't wait to get it out on the road and test it out. Here's how I did it.
First, things first. Make sure everything's there.
Black arrow: Ballast power cable, Red arrow: HID Bulb, Green Arrow: Ignighter, Blue arrow: Ballast.
The first thing I noticed when I put the bulb in the headlight housing was that the spring to hold the bulb down didn't contact the HID bulb hardly at all:
To fix this issue, first pry the stock bulb out of the adapter with a screwdriver:
Then, using a hacksaw, cut the base off the adapter:
Notice the tabs left over. Break these tabs off and slightly enlarge the hole so it will fit over the HID bulb.
Slide the base over bulb and attach the hold down spring:
Now, since the adapter we just cut up is what suzuki used to seal the dust/water cover to the bulb, we need to replace it with something. I'm sure there are much better ways to do this, but this is what I did using things I had in the garage. (didn't wanna spend much more than I had to)
I started with a rubber piece from a sway bar end link:
Cut it down so it will fit into the hole in the dust cover:
Cut a slit in it so you can slide it over the wires:
Sand it down to smooth it out so it'll fit tightly against the dust cover:
Slide it over the wires and insert it into the dust cover (these next few pics were taken on a test fit before it was sanded):
Push it down till it's flush with the back of the dust cover:
Next, install the dust cover on the headlight housing:
I used window and door caulk to seal the hole in the end link rubber:
Now for the wiring of the relay. First, install a female blade connector on the orange wire, a male blade on the black with white stripe, combine the red and yellow wires in a male blade, use a ring terminal on the black wire, and isolate the brown wire (this wire is not used)
Connect the orange wire from the relay to the white wire from the ballast.
Cut a section of wire the same length as the relay wires and install a female blade on one end and a ring terminal on the other:
Connect this wire to the black wire from the ballast and encase with heat shrink:
Next, cut off the headlight connector and install female blade connectors on each wire:
Connect the red/yellow wires from the relay with the white wire from the headlight circuit, and connect the black with white stripe to the black wire from the headlight circuit, then cover both connections with heat shrink. This before and after in the same picture:
Bundle the wires together and tie together. Remember to leave the black wire from the ballast by itself:
Install the harness back in the cowl, secure all the extra wires. Velcro the relay to the cowl where the blue arrow is. I installed it where it is in the picture and it was too high. It hit the frame around the cluster. Lowering it to where to arrow points will fix this problem. Velcro the ignighter on the side of the headlight housing where the green arrow points. I forgot to take a picture after installing it:
Attach the ballast with velcro and a vacuume drive belt to the right air intake tube. (I used a belt for an oreck xl)
Add the ring terminals to the mounting bolt for the right side intake tube. (these are the black wire from the ballast, and the black wire from the relay) Also, make sure that the ring terminals are between the plastic of the tube and the HEAD of the mounting bolt. Otherwise you won't have any ground.
Here's a view of where I mounted the ignighter.
And the finished product!!!
Here's a diagram of how to wire the relay. "bike" refers to the headlight connector wires and "bal" reffers to the ballast wires.
First, things first. Make sure everything's there.
Black arrow: Ballast power cable, Red arrow: HID Bulb, Green Arrow: Ignighter, Blue arrow: Ballast.
The first thing I noticed when I put the bulb in the headlight housing was that the spring to hold the bulb down didn't contact the HID bulb hardly at all:
To fix this issue, first pry the stock bulb out of the adapter with a screwdriver:
Then, using a hacksaw, cut the base off the adapter:
Notice the tabs left over. Break these tabs off and slightly enlarge the hole so it will fit over the HID bulb.
Slide the base over bulb and attach the hold down spring:
Now, since the adapter we just cut up is what suzuki used to seal the dust/water cover to the bulb, we need to replace it with something. I'm sure there are much better ways to do this, but this is what I did using things I had in the garage. (didn't wanna spend much more than I had to)
I started with a rubber piece from a sway bar end link:
Cut it down so it will fit into the hole in the dust cover:
Cut a slit in it so you can slide it over the wires:
Sand it down to smooth it out so it'll fit tightly against the dust cover:
Slide it over the wires and insert it into the dust cover (these next few pics were taken on a test fit before it was sanded):
Push it down till it's flush with the back of the dust cover:
Next, install the dust cover on the headlight housing:
I used window and door caulk to seal the hole in the end link rubber:
Now for the wiring of the relay. First, install a female blade connector on the orange wire, a male blade on the black with white stripe, combine the red and yellow wires in a male blade, use a ring terminal on the black wire, and isolate the brown wire (this wire is not used)
Connect the orange wire from the relay to the white wire from the ballast.
Cut a section of wire the same length as the relay wires and install a female blade on one end and a ring terminal on the other:
Connect this wire to the black wire from the ballast and encase with heat shrink:
Next, cut off the headlight connector and install female blade connectors on each wire:
Connect the red/yellow wires from the relay with the white wire from the headlight circuit, and connect the black with white stripe to the black wire from the headlight circuit, then cover both connections with heat shrink. This before and after in the same picture:
Bundle the wires together and tie together. Remember to leave the black wire from the ballast by itself:
Install the harness back in the cowl, secure all the extra wires. Velcro the relay to the cowl where the blue arrow is. I installed it where it is in the picture and it was too high. It hit the frame around the cluster. Lowering it to where to arrow points will fix this problem. Velcro the ignighter on the side of the headlight housing where the green arrow points. I forgot to take a picture after installing it:
Attach the ballast with velcro and a vacuume drive belt to the right air intake tube. (I used a belt for an oreck xl)
Add the ring terminals to the mounting bolt for the right side intake tube. (these are the black wire from the ballast, and the black wire from the relay) Also, make sure that the ring terminals are between the plastic of the tube and the HEAD of the mounting bolt. Otherwise you won't have any ground.
Here's a view of where I mounted the ignighter.
And the finished product!!!
Here's a diagram of how to wire the relay. "bike" refers to the headlight connector wires and "bal" reffers to the ballast wires.
