Okay guys, I know installing HID's has been covered a bunch of times for all years of the r6, but they all show you how to drill the headlight in order to run the wiring. Well here I'll show you how to install your new HID's WITHOUT any drilling. The install looks factory, and works just like the factory intended. So here goes:
First off here's what you'll need for tools:
1. Soldering iron and solder
2. #11 X-Acto knife blade
3. Jewelers screwdriver set (small flat blade is what's needed)
4. Wire strippers/clippers
5. Lighter/heat gun
6. Multimeter
Here's what you'll need for materials:
1. Patience
2. 2 bulb HID kit (I got mine here:
http://stores.ebay.com/sogoestore_W0...2BSI%26otn%3D4)
3. Various sizes of shrink wrap
4. Patience
5. rubbing alcohol
6. 2 Plastic sandwich bags
7. Sharpie marker
First off, you'll need to remove your headlight from your bike. This I know is a PITA, but it's removal is mandatory for the amount of handling you'll be doing with it.
When you have the headlight removed, it'll look like so.
IMG_1079.JPG
Remove the bulb covers and the bulbs, taking care to place each of the bulbs in its own platic bag WITHOUT touching the glass.
Now take your jewelers screwdriver kit out and find a small flat bladed screwdriver, one with a blade size of about 1/16". With the factory blue plug in the orientation shown below:
IMG_1080.JPG
Use the screwdriver to pry up on the small retention tabs that hold each pin inside the plug. When you lift the small plastic finger or tab, pull the wire from the back side and it will release from the plug.
IMG_1083.JPG
Now take the factory wires and pull them from the outside in, through the small rubber grommet, then remove that grommet.
Here's what you should have:
IMG_1087.JPG
Your HID kit will have weather tight plugs for both bulb leads, these need to be removed. Now take the smallest flat screwdriver you have, and if applicable, remove the colored inserts which lock the pins into thier respective plugs.
IMG_1061.JPG
After the colored locks are out, remove the pins entirely from the plugs. This will take some playing, just be patient and keep working, they'll come out.
Once you have the pins out of the plugs, pull the leads out of the HID grommet, and then push them through the small factory grommet that you took out of the headlight previously and then install the assembly from the inside out, in the headlight. BE CAREFUL TO OBSERVE THE CORRECT ORIENTATION OF THE GROMMET AND THE BULB HARNESS BEFORE YOU ASSEMBLE IT AND THEN INSERT IT INTO THE HEADLIGHT. Make sure the grommet is fully seated and then remove the protective cup that comes on the bulb, seat the bulb in the socket and then place the retention spring down onto the bulb. It's should look like this:
(the alcohol is used to clean the bulbs if you should happen to touch them accidentally during installation)
I'm writing this How-To after I've done this mod, not during. As a result, the following parts don't have before and after pics.
You'll need to take your multimeter and the blue plug you removed from the halogen bulb harness with you over to your bike. Start the bike up and then use the multimeter to determine which one of the leads is the positive one. Once this is done, transfer that orientation with a sharpie marker to the blue plug from the bulb. This will tell you which side is the positive for the harness you'll be making next. Be sure to do this for both the low and high beams if you're changing both.
Return back to your work area and then firmly re-install the bulb harness pins into its blue plug (the polarity is irrelevant). Then take your wire cutters and clip both wires so that they have approx. 1.5" remaining. Strip these wires and then tin them with your soldering iron. Now take the powerharness which came with your HID kit and cut it down to about 1.5", strip these wires and then tin them as well.
You'll need to cut 2-1" long pieces of 1/8" diameter shrink wrap which just fits over the wire, then also cut 1-1" long piece of 3/8" shrink wrap which will fit over both pieces of shrink wrapped wire.
Observing the mark you placed on the blue factory plug to indicate positive polarity, solder the positive wires together, then shrink them. Do the same with the negative wires, and then slide the large piece of shrink over both joints and shrink that. This is what you should have:
Once you have the harness done, reassemble the bulb plugs and place the bulb covers back on.
Now it's just a matter of plug and play with your harnesses...
From here you'll have to reinstall your headlight and find your own place to mount your ballasts, but once back together, your HID's will look factory. This mod was done with 2 separate bulbs to take advantage of the high-low beams, if you use two bulbs as well, you'll notice a slight delay in the high beam when switched on. This is a result of the bulb needing to heat up for a few seconds to get maximum light output. This only comes into play when you switch the bulb on and off frequently during night driving.
If you guys have any questions, feel free to drop me a PM.
Factory looking HID's: '06-'08 race version
Looks like i'll do it your way and pull the headlight if/when it blows.
Linear Mode
