Installation

Fitting to Motorcycles
When fitting to bikes, do it in 3 separate steps

(1) Remove the headlight unit and do the fiddling around with the burners that way. Trying to fit the new burners without removing the headlight unit is a recipe for frustration swearing and skinned knuckles? and therefore misery. You will also need a 23-25 mm (1 inch) drill bit (you need to make a circular hole on the back of the headlight units two round caps.)

(2) Find where you want to locate the ballasts, and mount them- make sure they are close enough to the headlights for the cables to reach - it's near impossible to extend them. I have my 1200 GSA headlight ballasts between the screen and the back of the instrument panel. Others have chosen different locations. There is no best answer. But do note that if you mount under the oil cooler on a GS or GSA, the forks move forward under compression, so the ballasts can not project further back than that rear edge of the oil cooler. Some end up getting custom brackets made up for the ballasts, while my preferred option now that we have moved exclusively on to ultra-thin ballasts, is just to mount them with 3M VHB (Very High Bond) double sided tape or 3M VHB Dual Lock industrial velcro. Everyone seems to find different locations to mount the ballasts. You have to be creative with motorbikes re ballasts mounting. There is always room though, I have 6 ballasts on my 1200 GSA - you just have to find the room.

(3) Connect everything up. And power up !

Note that sometimes the kits come with slightly different wires that are nominated in the installation booklets. The booklets refer to red being positive and black negative. Usually that's the case with the kits but occasionally I get kits with blue and black wires. In those examples, the black wire remains negative, and the blue wire is positive.

Here it is again in a bit more detail:

HID Conversion Kit Installation, for BMW motorcycles.

1. Remove Headlight unit from motorcycle, ensuring motorcycle is switched off. No need to remove battery.

2. Unscrew the plastic caps at the back of the housing that provide access to the bulbs.

3. In the centre of the two plastic caps that were removed earlier, drill a 23-25 mm (1 inch) hole (with a hole saw bit or a flat wood bit).

4. Unlatch the bulb retaining spring clip, and remove the old halogen bulbs. The plastic that holds the spring clips is brittle and prone to break. Be careful.

5. Pass the bulb and two wires with open spade connectors through the newly drilled out hole in each plastic cap until the rubber grommet is seated in the newly drilled hole.

6. Insert new HID bulbs, ensuring they are correctly aligned. Note that the 4 wires will slide back and forwards through the grommet. I advise that when you are fiddling around getting the bulb in, that you pull as much wire to the bulb side of the grommet as possible to avoid skinned knuckles and excess frustration. When seating the new bulbs, the H1 is hard to get wrong, but the H7 is easily gotten wrong. Make sure the bulbs are correctly seated before closing the bulb retaining spring clip, again taking care not to damage the poorly made housing around the base of the spring clip.

7. Connect the spade connectors up to the motorcycle's headlight power. (see 8 and 9 below for H7 and H1 respectively)

8. The spade connectors attach to the contact block that previously plugged into the back of the bulb. On a H7 kit, the brown BMW wire (negative) needs to lead to the black spade connector wire (negative). And the white or yellow BMW wire (positive) needs to connect to the blue or red spade connector wire (positive).

9. On a H1 kit, the BMW earth is plugged to the headlight housing and needs to be removed before connecting to the black spade connector. They may need to be crimped together with a pair of pliers if they are different shapes. The wire that connected to the H1 bulb is the positive and needs to be connected to the blue or red wire's spade connector.

10. Plug the wires that come from the bulb into ballasts with the - its impossible to plug in the wrong way - check the connectors and check the HIDs have been wired up correctly by turning the appropriate lights on. Note both ballasts in the kit are identical, so you do not need to pair a particular ballast with a particular bulb.

11. Close up the headlight unit by screwing back in the plastic caps. Note that the 4 wires will slide back and forwards through the grommet. It is advisable to pull out excess wire from the headlight housing as you close the unit, to avoid having too much crowded wiring inside the cramped headlight housing. Similarly, I advise that when you are fiddling around getting the bulb in, that you pull as much wire to the bulb side of the grommet as possible to avoid skinned knuckles and excess frustration.

12. Next stage - mounting the ballasts. It?s really up to each individual to mount ballasts and a number of different brackets and locations are possible. Make sure the ballasts are mounted so that their cables can comfortably reach the appropriate bulbs. The ultrathin kits are can be screwed or otherwise attached to a flat clean surface.

We have instructions and images for different model bikes, which we can supply

Note: BMW's have unique wire colours.

White wire : high beam positive

Yellow wire : low beam positive

Brown wires : earth (negative)



HID50 on a KTM 990 Adventure and a BMW K1200R



HID50 on the BMW F800GS (low beam / high beam)



HID50 on a Triumph Tiger

Brackets
There are our custom made ballast mounting brackets available for the BMW 1200 GS and GSA.



Above: The 1200GS bracket. Its versatility is that it was be able to handle any ballasts, large or small. This is useful if you ever need to change to a different style of ballast at a future date. Its upgrade friendly. You can fit up to 4 of the new UltraThin ballasts side by side on our bracket ideal for doing the fogl ights as well.



Pics above: The HID50 bracket fitted with UltraThin 50w ballasts

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Fitting
If you don't fancy fitting your own HID set, we can put you in touch with people who can fit your HIDs to your headlights.