tidbit 02-20-2003, 02:44 PM ***NOTE*** This How To was written by kevo!. I am reposting it in here.. because it's a great example of "How To" make a great HT post. :thumbup kevo if you want to repost this under your name.. Do so and I'll delete this thread.. :yesnod
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Here's my installation guide.
1. Remove both front seat and passenger seat.
2. Disconnect battery.
3. Disconnect tail light, turn signals, and license light
4. Remove undertail.
5. Remove rear fairing.
6. Locate a good location for the control unit. . The control unit is not water tight, so a dry location should be selected. To change the pattern of the brake or turn signals, the unit and rotary switches must be accessible
tidbit 02-20-2003, 02:44 PM 7. Remove rear tail light housing from frame.
8. Using a knife or razor, score between the light lens and the black base. You should have the glue scored about half way through.
9. Using a hammer and small flat head screwdriver, tap screwdriver head between the light lens and base. You will be able to tell if the screwdriver head penetrated through the glue. Once you have penetrated the glue, continue around the base no more than 1/8” from the first penetration. Be very careful or you could crack the light lens or the base. The super-glue that was used will cause the plastic to be brittle.
10. Once the lens is separated from the base, use the screwdriver to scrape the residual glue from the lens and the base. Wipe off any glue dust and set the lens aside.
tidbit 02-20-2003, 02:45 PM 11. Push the rubber grommet out from the hole and remove the screws holding the LED board.
12. Cut off the wires from the tail light approximately 3-4” from the board. You should leave enough wire to crimp the wires from the LED board, should you need to reinstall it. This will also give you enough wire from the 3-pin connector to reach the new control unit.
tidbit 02-20-2003, 02:45 PM 13. Cut off the factory connector from the two turn signal lights, leaving approximately 3-4” of wire from the connector.
tidbit 02-20-2003, 02:45 PM 14. Using the connectors provided, connect the RED wire from the control unit to the factory BLUE wire. Connect the BLACK wire from the control unit to the factory BLACK wire. Connect the GREEN wire from the control unit to the YELLOW factory wire.
15. Connect the YELLOW wire from the control unit to the factory GREEN wire from the turn signal. There are two wires on this factory connector. Tape the black wire off, as it is not used. Connect the BLUE wire from the control unit to the factory BROWN wire from the turn signal. There are two wires on this factory connector. Tape the black wire off, as it is not used.
tidbit 02-20-2003, 02:46 PM 16. Connect the control wires to the control unit and LED board.Test the operation of the brake lights and turn signals before proceeding.
17. String the two control wires through the light base.
tidbit 02-20-2003, 02:47 PM 18. Cut the factory grommet in half at the point where it increases in size. Cut the center out of the larger half. Do not cut too much and make sure you cut enough out of the middle for the grommet to go over the two control wires on the inside portion of the base.
19. Connect the control wires to the LED board. Mark the wire that is connected to the socket with the white dot. Use tape or making pen. This control wire will be connected to the control unit pins with a corresponding white dot.
20. Then mount the new LED board to the tail light housing base, pushing the grommet back into the hole. Make sure that the board sits on the three factory pins. These align the LED board in the housing.
21. Using super-glue, place a few dabs of glue around the light base. Place the lens on the base and hold together until dry.
22. Once the super-glue is dry, place a small bead of silicon around where the lens and base meet. The bead should be flat and no higher than 1/32”. Dip your finger in soapy water and smooth out the bead, pushing it in between the lens and base.
23. Seal the outside portion of the hole where the wires are coming through with silicon. Allow silicon to dry.
tidbit 02-20-2003, 02:47 PM *
tidbit 02-20-2003, 02:48 PM 24. Remount the tail light assembly on motorcycle.
25. Route control wires back to control unit and plug them in. (NOTE: Connect the wire that you previously marked, to the side with the white dot)
26. Use the zip ties provided to secure loose wires.
27. Reinstall rear fairing, undertail, and seats.
As you can see, I used as much of the stock heat tubes as possible. I also went out and bought some heat tubes from Napa. Ouch! $34.00. But it is heat resistant and shielded on the inside.
It was used more for waterproofing and abrasion protection than for heat protection. And it made the installation much cleaner.
See the photo below. The other black wires on the right side are from an Aritronix Alarm. They used many of the same connection points, so they shared the tubing.
Also, you can see where I mounted the control unit. If you sort the tools in the tool pouch neatly, there is more than enough room in that area. It also provides more protection for the control unit and leaves more space in the tail section. (See the first photo)
tidbit 02-20-2003, 02:49 PM NOTE: If you have other aftermarket goodies like Gregg's flushmounts, be sure to have an upgraded flasher before you begin.
The tail light worked when I tested it. It was after I completed the installation and decided to install my Gregg's flushmounts, that the tail light stopped working like it was supposed to.
More photos: Sealing the light housing.
tidbit 02-20-2003, 02:50 PM To order this Taillight Kit.. Go to www.hightechspeed.com :thumbup
twowheeldrft 02-18-2004, 06:16 PM sweet just what I was looking for
over_dose 02-28-2004, 03:45 PM bad ass post. :thumbup Thanks. I've got mine on order but was sitting here looking at the sealed brake light assembly and getting stressed out. This is going to save me a lot of trouble. Can you tell me what kind of upgrade flasher/relay? you are talking about? I was going to use Greggs flushmounts also.
mgraham224 03-16-2004, 01:43 PM Can we ge this sticky'd
over_dose 03-20-2004, 10:09 PM Just did mine today. I dont know if this was an old kit but my unit came with matching wires which made it a snap. There was a blue/black/yellow/brown/green harness. The only trick was cutting the wires to the turn signals and matching them up with the proper side. I didnt re-install the license plate light either.I also installed the libertek flasher relay which works great to settle the speed for the flashers. I dont know if it makes a difference or not but I also left the resister attached from the factory to the Led board. oh yeah... the thing looks sweet now:rock
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