Yamaha 1300 Tourer - Yamaha 1300 Tourer Fansite

Just finished installing the HID Country H4 Bi-Xeon dual intensity motorcycle HID conversion kit on my 09 tourer. The difference in light output is fantastic. Installation was not too difficult but was very time consuming. I would say install took me about 5 hours, with most of that time spent monkeying around with component placement to make sure nothing would bind up once everything was installed.

This is a guide for installing the HID Country H4 Bi-Xeon Dual Intensity motorcycle HID conversion kit. This kit took me about 5 hours to install, with most of the time being spent on positioning the components to prevent binding.

The kit comes with the following pieces.

Replacement bulb:

Harness:

Ballast:

Here is an expanded view of the harness. Basically, the harness will connect to 12v power, ground, the ballast, the new headlight bulb, and the factory headlight harness. The ballast also has two wires which will connect to the new headlight bulb:

Before you begin, it might be a good idea to put a towel or cloth over your front fender. I don't like scratches, so I had a towel on my fender the whole time.

First we need to remove the trim cover for the turn signals.

Remove the left bolt:

Remove the right bolt:

There is a plastic tab in the center of the trim piece that pushes into a rubber grommet. Pull the piece
straight forward to remove it:

Now start removing the screws around the headlight assembly:

There is a tensioning clip at the bottom of the housing you may also need to loosen. You do not need to completely remove this screw, just loosen it a bit:

Now you can gently pull the headlight out of the bucket. Once clear of the bucket, unplug the headlight from the wiring harness.

With the headlight removed, we can remove the weather tight boot. This will simply pull off of the headlight assembly:

Release the retaining clip:

Pull out the old bulb:

Insert the new replacement bulb into the housing, lining up the pins (it will only go one way):

Now latch the bulb in place. You might have to gently bend the retaining clip around the body of the bulb. It will fit.

Now, since the new bulb is larger than the stock one, you can't fit the boot over the bulb. So we will take the bulb apart. With the bulb fitted into the headlight, twist the bottom of the bulb about 1/4 of a turn, you will feel the rear section of the bulb separate from the piece locked into the headlight. Carefully remove this from the headlight making sure not to hit the now exposed bulb on anything:

With the rear of the bulb removed, you can reinstall the weather tight boot. The fit is snug, but with some fiddling you will be able to get it around the bulb base. Be careful not to drop anything inside!:

Now, with the boot inlace, reinsert the half of the bulb you removed and twist 1/4 turn to lock in place. This is a keyed connection and will only work one way, so just twist until you feel it drop into place, then its about a 1/4 turn to lock in place:

Now the headlight is done. Place that to the side and out of the way for now.

For the next steps, I found it easiest to remove the gas tank to be able to properly wire everything. However, I couldn't manage to remove the tank and take pictures myself. In a nut shell:
* Remove the drivers seat
* Unbolt the two bolts at the rear of the tank
* Disconnect the wiring connection at the rear of the tank
* Disconnect the two large hoses from the tank. One from the tank shut off (remember to turn this off) and one from underneath the seat latch.
* Now the fun part, slide the tank slightly to the rear of the bike, this removes the tank from the forward mounts.
*Lift the tank up slightly, then roll it over toward the left side of the bike. With the tank tilted 90 degrees to the left, you can reach under the tank and disconnect the two hoses that connect to the underside of the tank. Mark these two lines so you can put them back in the correct order.

With that done, back to wiring. Remove the front forward panels. They are each held on with 1 bolt and a panel pin.

Put some double sided tape onto the back side of the large ballast.

Slide the ballast along the right side of the front frame as shown. I tried this on the left side of the frame first, but there is a mounting pin in the way that prevent the ballast from moving to the rear enough. So if you choose this mounting position, you are limited to a right side install.

Once slid as far in as possible, press firmly to seat the tape:

Apply more double sided tape to one side of the small ballast box. This will get taped right in front of the first ballast. You may want to dry fit this with the side panel to make sure you have your placement correct:

Take the wiring harness by the relay and pass it through the frame just below where you attached the ballast:

There is some wiring tucked into the front of the frame which you can zip tie the ballast harness to:

At this point, you can run your harness RED wire along the frame to the battery to pick up a 12v source.

There is a black ground wire which I put under the bolt right next to where you just attached the relay. You will see a small tab on the frame with a mounting tab attached to it. Just back out the bolt, slip in your ground, and tighten it back up.

Plug your ballast and harness together. I then taped this up with electrical tape so no red would be showing. Run the remainder of the harness wires and ballast wires up to the rear of the headlight bucket. I passed all of the wires through some plastic wire loom to keep things neat:

Inside of the headlight bucket, you should have just enough slack to get the four connectors into the rear of the head light bucket. Don't worry if it seems like not much slack. There is a lot of slack on the headlight itself which will make the cabling plenty long. Holding the headlight up to the bucket, make the four connections:

* Connect the factory harness headlight plug to the new harness

* Connect the small, two wire connector from the new harness to the new bulb

* Connect the male lead from the ballast to the female lead on the new bulb

* Connect the female lead from the ballast to the male lead on the new bulb.

Its hard to see, but here is the headlight with all the connections made:

Now carefully put the headlight back into the bucket. There is plenty of room, just go slow to make sure you don't pinch anything.

Now reassembly is reverse of disassembly.

Attach top two headlight screws:

Attach bottom two headlight screws:

Snug the center retaining clip screw if you loosened it:

reinstall trim piece by lining up the pin and attaching the two screws:

You can reinstall your gas tank now too.

Fire up the bike and test it out. I think you will really enjoy the added night time visibility this gives you. I have only rolled out in the dark once so far with the new lights installed and man what a difference this makes. For $50 plus some time tinkering, this turned out to be an excellent improvement in one of the few areas I feel this bike is lacking.