RELATED MODS: POD Lights

Notes about this mod:

These HID Kits - This HID kit was originally purchased from this eBay Seller and they do not mix and match H4 and H7 units. So the original FZ6 Forum member who did this mod (Gozilla) had to purchase TWO kits, one H4's and one H7's, then use one projector from each kit and leaving him with an extra set of projectors which he then put up for sale on eBay and I purchased. So if you are thinking of doing this mod, you might want to team up with another FZ6 owner also wanting to do this mod and each get one set (one get the H4s, the other the H7s) and then send each other the extra projector.

Ballasts - 2 Ballasts are needed for this mod and they are NOT included with these HID kits and must be purchased separately. I bought mine from this eBay Seller. I am also considering finding some SLIM ballasts as the ones I purchased are full sized ones and smaller ones would be much nicer to have!

A big thanks to member 'Gozilla' and his post about Bi-Xenon H4 & H7 HID projectors and for selling his extra H4 & H7 projectors, I decided to tackle this project. http://www.fz6-forum.com/forum/fz6-m...installed.html (Bi-Xenon projector with angel eye installed)

This is probably the biggest electrical mod I've undertaken and the task seemed daunting at first. My biggest concern was finding physical space for mounting two sets of controller units and two ballasts in the front fairings...along with my already mounted Stebel Horn, POD light and LED blinker wiring and relays. So after thinking about it for several weeks now, I said "screw it" and just dove in and went for it. The attitude I take when doing a mod is that I'm going to do it and make it work; period. Any issues I run into along the way are just problems that can be solved.

Removing and taking apart the front assembly/headlights wasn't that bad and thank god I put quick disconnects on all the previous wiring mods I've done!

Next to finding space to mount stuff, the whole "headlights in the oven" thing freaked me out the most, but as it turns out, it was really an easy process.

200 deg for 20 minutes and the lens covers pulled right off!

Once the lenses were off, I fully committed myself to doing this mod by painting my reflectors black. I like the look of HID projectors with a black background. Since these projectors still need the reflectors for mounting and you can't remove them, I decided to paint them black (the projectors don't use the reflectors).

After the paint dried overnight, I installed the projector housings into the reflectors.

Using the supplied lens sealant, I re-attached the lenses.

Then I re-assembled the headlights back into the front faring. This made it quite easy to work on and to figure out where to place and attach everything in the kit.

Welcome to my wiring nightmare!

Right side (H4)

Left Side (H7) - VERY crowded with having the Stebel horn here too, but I did manage to get everything in place. Needless to say, but the left side is now full up!

mounted the ballasts using industrial Velcro with adhesive backing. This way it holds them secure, but i can remove them easily if I need to replace them.

I managed to get the entire front assembly back on and bolted onto the bike last night and completed most of the wiring on the right side (the easy side). I'm taking my time with this mod as there is a fair amount of wiring to do and at the same time I am re-working and cleaning up some of my other wiring from my POD lights/switch and horn wiring. i figure another few evenings and I hope to be done and riding again by Thursday.

The nice thing about this retro fit HID kit, is that you can use the existing headlight aiming adjustments for moving and aiming the new projectors since they are mounted into the adjustable reflectors!

Right side all wired up and ready to go.

Left side wired up.

A much nicer looking front end!!

Ok, thought I was almost finished, turns out I'm not.

Finished wiring everything up last night, fired it up and it seems the H4 side Angel Eye filament does not want to fully light up! It starts to glow, but won't fully light. Kind of like a fluorescent tube that struggles to light up. Kinda pissed.

Here is a pic of what I'm talking about :

I've checked the voltage and the angel eye wiring and it all seems fine. the other unit is wired up the same and measures the same voltage and it's working fine.

I am going to be contacting the eBay seller (not Gozilla, but the guy who sold him the units) and see if I can either get a replacement Angel Eye element or a replacement H4 projector housing. Of course that means taking everything apart again, re-opening the lenses and swapping out the projector unit. Not as bad as one might think as everything is wired and in place so it would involve just disconnecting a few wires (I use quick disconnects on most of my connections) and everything removes in place with the whole front end. So maybe 1.5 hours to remove, swap projectors and put back on. Not too bad really.

Other option (the easy one) is to just disconnect the Angel Eyes which I am doing for now. They are more "cosmetic" than functional so it' not a huge loss in the big scheme of things.

I got the wiring figured out for Low-Low and High-High!! Basically doing what 'Gozilla' said about creating a 2nd headlight harness off the right side H4 harness. Here is a picture to illustrate what I did. Thanks to 'ant_mb' as well for his info and pics he sent me. If anyone see's a problems with this, please let me know! Instead of splicing and creating a whole new wiring harness, I just rewired the existing left side headlight connector to basically be a duplicate of the right with the added and shared 3rd (top) wire used from the dual headlight mod. Not 100% sure how or even why this works, but it does so I'm going with it!!

This was the original diagram/instructions that Gozilla made. I essentially did this.

Finished results! I LOVE the new look of the front end! I can honestly say that I never really liked the look of the FZ6 front end, even with the PUIG screen. Now however, it looks much better!

Video:

Low Beams

High Beams

Turning Nighttime into Daytime!

Aiming HID Projectors

Now that you have your HID projectors installed, you need to properly aim them. I've been scowering the Internet for instructions on how to aim HID headlights after my recent HID Projector conversion. Here are what I've found to be the most consistent method.

TO AIM HID PROJECTOR HEADLIGHTS:

1. Align your car dead center in your driveway....the front and back of your car need to be perfectly aligned in the center.

2. Pull your car up to the garage door...as close as you can get w/o hitting the door..dead center in the middle of the garage door / driveway.

3. Put a piece of tape where the headlight beams hit the garage door. This should only be small dot of light.

4. Pull you car back 25'. Your Projector lens should be 25' away from the garage door...not your tires or your bumper...your headlights. DEAD CENTER IN THE DRIVEWAY

5. With tape Place a VERTICAL line that intersects each piece of tape that you put on the garage where your headlight beams hit. Use a yardstick or a straight edge t make it perpendicular to the driveway. This is important for aiming your lights right to left....this is just as important as up and down because if your lights are aimed to far left you will still be shining oncoming traffic in the eyes and if they are aimed too far right your not getting the most out of your light.

6. With tape place a horizontal line along the garage that intersects each piece of tape that you put on the garage where your headlight beams hit. They should both be the same height off the driveway.

7. With tape place a horizontal line along the garage that is 2.1" lower than the tape you placed on the garage in instruction #6. This line should be parallel with the line in #6...just 2.1" lower.

8. Cover up the passenger side headlight with a thick towel.

9. Turn on your lights

10. Drivers Side UP/Down: Bring the lower step of the cutoff to or below the tape line that is 2.1" lower than your headlights...Dot Spec is 2.1" to 2.5" drop over 25'

11. Drivers Side Right / Left: The Vertical line on the drivers side of the garage should intersect the middle of the slant on the cutoff. Move the beam pattern until this is the case.

Moving the projectors from right to left may effect the height of the beam pattern. If this is the case..just go back and fine tune.

12. Cover the Drivers side headlight with a thick towel.

13. Repeat the UP/Down Left/Right procedure that you did on the drivers side with the passenger side. The vertical line on the passenger side of the garage is to be used for intersecting the slant in the cutoff on the passenger side headlight beam.

- Boneman