Mounting the HID lamps became a somewhat of a problem. Although the "Top Gun" mounts, (as described in the article) were readily available, for mostly aesthetic reasons, I chose not to use them.
I prefer positioning the lamps lower and more centrally located within the frontal area of the machine. There is arguably some logic to installing projection type lamps in this location, (as opposed to high and far apart Top Gun Style). Mounting the lamps low minimizes the illumination of moisture laden air. Fog lamps and driving lamps are always mounted in such fashion, (closer to the road), providing the most effective far reaching penetrating beam.
When mounted "Top Gun" style, the Phillips HID lamps should also provide more illumination towards the edges of the highway, however, I chose to rely on the FJR's stock lamps to fill this void.
To mount the HIDs' I designed and fabricated the an aluminum bracket, (the "Stealth Shelf"). Mounting this bracket to the FJR, requires the removal of the windshield, upper, middle and lower faring sections and finally the head lamp nacelle.
I'm sure there many resources to describe the removal of said plastic parts, so I'll assume for the moment the plastic components have been removed. One note of advice, the nose section of the faring has one centrally located self thread screw holding it to the head lamp assembly. Access to this fastener requires that the headlamp nacelle is removed from the bike.
The attached photos reveal where the Stealth Shelf mounts to the machine as well as the unique location of the lamp ballasts.
To secure the ballasts within the headlamp housing, I first prepared the housing by using a small high speed grinding bit. I made two small slots on the web between the lamp housings just large enough to thread through a nylon tie wrap. In addition to the tie wrap, I used double sided foam tape to assist holding the ballast's in place. I also used thick silicone rubber pads for spacers and shock absorbers.
So that the ballasts will fit into the headlamp nacelle, the two rear mounting tabs must be cut off. The ballasts are positioned within the headlight nacelle so that the connectors are facing outward.
Connecting the wiring harness and the PIAA LED switch provided from Micatech was simple and straight forward. Using the double sided foam tape supplied by Micatech, I located the PIAA switch on the rearrearface of the handlebar mounted brake fluid reservoir.
As the wiring supplied for the lamps is quite long, I trimmed the unnecessary excess. I don't like bundling extra wire, and the reduction in length reduces the D.C. resistance, (minimizing losses).
Oddly enough, there are holes in the black PVC inner faring panels that were very convenient for routing the lamp wires. I chose to use solderless quick connectors on the cable from the lamps to the ballast's. In this way, subsequent and complete removal of the lamps can be achieved by only removing the black PVC panels and disconnecting the wires.
After the first installation using the original Phillips lamp brackets, I discovered a minor glitch. Under full fork compression, the front fender would make contact with the rear of the lamp housings. To eliminate this, I designed and fabricated two new Stealth Brackets that reposition the lamps farther forward and outward.
I'm a fanatic when it comes to clean wiring and symmetrical layout. I reversed one of the igniters on the HID lamps, (as described in the "eyes of God article") and used 90 degree spark plug boots to provide a uniform water tight seal at the wire exit location on the lamp housing. I also discarded the original Phillips wire sleeving in favor of a more flexible and attractive silicone impregnated fiberglass sleeve.
Photos of the installation process as well as the final result are attached.
The Stealth Shelf is tooled from 5052 aircraft aluminum and is post anodized to prevent corrosion. The Stealth Brackets are manufactured from mild tempered 14 gauge steel and are black oxide.
If you have any questions or comments please do not hesitate to contact me via the email link at the top of this page.
Phillips ballast with mounting tabs cut off
Shows the part of the tabs that were cut off
The ballasts will go here, with appropriate padding
The two ballasts mounted between the headlight housings
Stock mounting bracket on left, custom one on the right
The large custom bracket
Finished result, side view
Copyright © 2004, by Mitchell Rhine and H. Marc Lewis. All rights reserved.