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522 viewsI used the top of the hole in the bolt where the Allen wrench entered.
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522 viewsConnect the wires to the power plug. Now all the ignitor and ballast wires are attached so you can push them further into and down inside the headlight bucket. Now you can loop in the other zip-tie to secure the ballast, cutting notches in the hourglass brace like I did if you want. If you removed the high-beam bulb you can now put it back in, along with its wires.
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Done!519 views
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518 views
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518 viewsRemoving the spacer.
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516 viewsFirst zip-tie installed. I waited on the second one so I could move the ballast a little while working on the electrical cabling. This just helps get the ballast out of the way and keeps it from moving around too much. You can now install the HID bulb and secure it.
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...after.515 views
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515 viewsPush in the power supply spade connectors into the headlight connector. As can be seen in the picture, I put the black wires together and the red wire with the white wire.
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515 viewsPush the power supply wires into the original headlight bulb connector.
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514 viewsMy fingers are pointing to the two pins that fit into the two rubber grommets that are part of the upper triple tree (visible in the foreground).
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514 viewsI used my engine hoist to lift my bike by the frame. I'm so glad I have this! This was necessary to get the full extension sag measurement as well as lifting the bike to take pressure off the lower bolt so it could be removed.
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513 viewsNow the bar-end mount is up two inches at 34" high.
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513 viewsConnect the ignitor wires to the bulb. One thing I did to make this wiring install easier is to remove the weather seal that holds the 4 wires. Since everything is contained within the headlight bucket there's no need for the wiring seal. Carefully use a sharp blade, like a crescent X-acto blade, to cut the seal and remove the wiring.
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512 viewsDetail of the bottom of the unbolted ladder.
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512 viewsHi-risers and controls installed, ready to put the bike back together.
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512 viewsUnscrew the bolts and remove the spring caps and springs. The pressure plate then pulls straight out and the push rod comes with it.
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512 viewsRemoving the one-way retaining washer is a pain in the butt. Chances are very good that you could end up breaking the pin...not that it's a big deal if that happens, honestly. I did this on the left side to remove the turn signal electrical connector away from the rest of the harness, then pushed the retainer back on.
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512 viewsFor safety I wrapped each connector in electrical tape and then wrapped them together as well.
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511 views
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510 viewsThe end result, push rod out.
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