Speedmetal H I D light kit installation in an 1100 Interstate

This is a 35 watt 6000k kit I bought from Cycle Gear.




Parts included.


Seems to have decent quality connectors.


First, remove the headlight bucket.
My adjuster knob is missing.


Pull the headlight out and unplug it.


Unclip the bulb retainer and pull the bulb out.


The tabs on the HID bulb were too large for the headlight notches so I dremeled the notches a bit wider.
I made the shell notches wider because vibration on the bulb narrowing the tabs wouldn't be good and a replacement bulb may be too large also anyway. A stock bulb still fits good.


Bulb in and seated. Have to bend the retainer clip around the large bulb body.


Then clip it in.


My test bed to make sure it works before install.




I'll install it tomorrow or this weekend and finish this thread.

:hihihi: that garage is insane ...it must be osha approved ..i dont think you can fall down anywhere in there

Dan, could you check the high / low beam one more time :smilie_happy: . It looks pretty cool. I'm anxious to see what you think of it installed in the bike :Egyptian:

I went with this 35 watt because I want to see how the lower wattage does because that's better for our stator.

Hmm, time delay relay? I wouldn't bother since I haven't seen any kits offered with one I figure the manufacturers don't think it's a problem. Besides, another relay is one more part to fail.
Supposedly we should get around 4 times the life from an HID so I think even if the cycling reduces it's life it will last a very long time.

I amped the actual wattage at 23 and 14 volts. Interesting.

"I always like to test these things before I hack the wiring and VOID THE WARRANTY." :smilie_happy: :smilie_happy: :smilie_happy: :smilie_happy: :smilie_happy:

KYWinger":14ye7xnf said:

Copy that....
Guess this is one more thing to do during winter down time - everyone, including you, seems to think this is the way to go, sooooooooooooooo.......

Click to expand...

I shined it outside, the low and high beam have a real nice beam spread. Definitely the way to go.

About the wattage.
Hid's will draw more as the warm up so my reading of 23 watts will no doubt go up. It was 40 degrees in the garage.

How hot does that thing get? Hot enough to be a problem with melting anything? I have an H4(halogen, I think) bulb I have been considering installing in mine, but it sure gets damn hot just hot-wiring it. I'm askeerd to put it in....

From what I've read, the hid bulb runs cooler than a halogen.
The heat is instead in the ballast (power box).

Dan, I read a post somewhere that said you could remove the shield on the bulb and that it gave better light without it. I have not seen the actual kit yet , just wondering why the shield is there covering the bulb? :headscratch:

stratocat":2dmvax7g said:

Dan, I read a post somewhere that said you could remove the shield on the bulb and that it gave better light without it. I have not seen the actual kit yet , just wondering why the shield is there covering the bulb? :headscratch:

Click to expand...

I'll have a look at the bulb.

The cover on the bulb does come off.
I think it might have something to do with the flatter beam it projects but I'll try both ways.
Ran into a snag though.
The longer bulb hits the fairing, can't even get the nut started.
Looks like I'll have to cut out the fairing for the bulb to go through to make it work.

Here's where I'm at so far.

I ran a separate 14 gauge hot and ground to the battery.
Need to pick up 2 eyelet crimps for the permanent connections to the battery.
Also, I put a better quality fuse holder on it. The one they provide is a bit chinsy.


Bundled the wiring then stuffed into the fairing.


Run the wiring out thru the existing hole behind the headlight.


The arrow points to where the bulb is hitting the fairing, dang nut won't even start on the threads so I'm gonna have to cut the back of the fairing for the bulb to stick out of.
Thinkin I'll cut it the diameter of a 2" ABS plumbing cap and glue it to the fairing.

The fun continues..........

I tried a smaller hole, bulb still hits..


So time to make it bigger.......

Pilot holes around the diameter of a 2" PVC plumbing cap...


This drill rasp is what I used to file it down so the 2" cap will fit thru......


Almost there...


Touch up a bit....


Headlight bolt in. The bulb clears good....


I'm gluing the 2" cap in place with black silicone.
It's cold here so the silicone is drying slow and of course I'm not going to post any pics of that until I've dressed it up some and the cap is secure.

Oh I did pull off the little metal blinder/shield thing from the bulb and it still shins a pretty flat beam.
Hard to tell if it's better to have it off or not. Will see when it's dark.

This clearance problem has turned out to be a very unexpected hassle but by the looks of the increased brightness and the nice beam I think it will be worth it.
I saw other HID bulbs that aren't as long but I think they would still hit the fairing after seeing how close the headlight is to the inside of the fairing there. I 'spect any HID would need the hole made.

Ok....got the 2" cap all siliconed in with the help of Mr heat gun to speed curing time.

I know, not very pretty, I don't care. It serves my purpose of giving the bulb enough room and so the headlight aim can be changed, it's water tight and secure.







Done!
Going to a party tonight so I'll try it out afterward or tomorrow night and report back.

Hi Dan, Sorry to see the installation was such a hassle. I sure hope its worth it in the end. I'm looking forward to your next post opcorn: