outasight20
Junior Member
I recently did this mod and wrote it up for one of my classes. the tutorial follows.
Bi-Xenon Projector Retrofit on a 2005 Yamaha FZ
The purpose of this tutorial is to guide you through the replacement of the stock 2005 Yamaha FZ6 headlights with a Morimoto Mini H1 Bi-Xenon Projection system. The information presented is specific to this installation; however, many of the steps are similar for other Japanese sport bikes.
Time to complete: 4-8 hours.
Required Materials
Purchased Kit:
Morimoto Bi-Xenon Mini Stage III Kit (H1)
Tools:
Metric Allen Wrench (4mm)
Metric Socket Wrenches (8mm, 10mm, 12mm, 14mm)
Flathead screwdriver
Philips Screwdrivers (#1, #2)
Wire Cutters
Needle nosed pliers
Equipment and Supplies:
Soldering iron and solder
Dremel tool with cone sanding attachment
Paper Towels
All-purpose cleaner
Electrical Tape
Loctite
Double Sided tape
Zip Ties
Oven and oven mitts
A. Removing Front Fairing
1) Using a four mm Allen wrench, remove the right and left inner fairing panels (three bolts each).
2) Turn handlebars full lock to the left, exposing the two 14mm bolts holding the fairing to the frame by the speedometer bracket. Remove these bolts.
3) Disconnect the wiring harness on the left hand side of the fairing (two plugs).
4) Lift and pull front fairing away from the rest of the motorcycle.
B. Extracting Headlight Unit from Fairing
1) Take off windshield by removing the five #2 Philips head screws located below the mirror boots (four) and underneath the front of the headlights (one).
2) Remove the four 10 mm nuts holding the two mirrors to the fairing. Pull off mirrors.
3) Remove two #1 Philips head screws located near mirror mounting holes.
4) Remove two #2 Philips head screws holding speedometer to top of upper fairing.
5) Remove four #2 Philips head screws holding speedometer bracket to fairing. Pull off speedometer bracket and carefully disconnect wiring behind speedometer (two plugs).
6) Unplug stock headlights and remove rubber boots behind stock bulbs on back of headlight unit.
7) Undo clips and remove both stock bulbs.
8) Remove five #2 Philips head screws holding headlight unit to upper fairing.
9) Carefully pull headlight unit out of upper fairin
C. Removing Lens Covers
1) Clean outside of headlight unit with paper towel and spray cleaner.
2) Heat oven to 200 degrees Fahrenheit.
3) Place cleaned headlight unit into oven for 20 minutes.
4) Carefully remove headlight unit using oven mitts.
5) Working quickly but carefully, work a flat head screwdriver around each lens cover, slowly prying cover off while unclipping tabs as you go around.
6) Repeat for other lens cover.
7) Place removed lenses aside, glue-side up.
D. Mounting Projectors
1) Locate the two projector units, along with the two “mini Gatling gun” shrouds.
2) Using the four supplied Philips head screws, mount the shroud to each projector unit.
3) Remove metal bulb holder from back of projector units by removing the three small Philips head screws on the threaded end of the unit.
4) Identify the correct metal adapter plate (H4 or H7) for each projector and test fit it. They may require a little bit of sanding with a Dremel tool to fit correctly.
5) Place the large silicone washer onto the end of the projector, then install it through the front of the reflector.
6) Place the small silicone washer onto the threads of the projector behind the reflector, followed by the adapter plate.
7) Apply Loctite to metal retaining nut, and carefully begin threading it onto the back of the projector.
8) As the retaining nut begins to tighten (needle nose pliers fit it perfectly and act as a makeshift wrench), start putting pressure onto the front lens of the projector, pressing it into the reflector housing and compressing the silicone washers as you continue tightening the retaining nut.
9) Mounting of the projectors is now complete. Clean the lens and reflector and rid the housing of dust and debris.
E. Re-installation of Lens Covers
1) Place completed reflector unit and two lens covers back into the 200 degree oven for about 15 minutes.
2) Working quickly, press the lens covers back into place, making sure all clips are re-attached; allow to cool for several minutes while keeping pressure on the lenses
3) Re-install metal bulb holder to back of projector units using the three small Philips head screws.
4) Carefully remove protective case and foam from HID bulbs and install bulbs into each projector (taking care to not touch the glass with your fingers).
5) Using supplied spring clip, secure each bulb into its projector.
F. Re-assembly of Front Fairing
1) Mount headlight unit back into front fairing with five screws.
2) Re-install rubber boots on back of HID bulb.
3) Re-install speedometer mount (connecting wiring harness), mirrors, and windshield.
4) Mount the ballasts with double sided tape on the inside of the fairings, or use desired method of attachment.
5) Connect Bulbs to ballasts.
G. Connecting Wire Harness to Battery
1) Lift up gas tank to expose battery by removing the two screws at the front of the tank and pivoting it upwards (A piece of string can be used to hold it from falling down).
2) Connect positive terminal from wiring harness to positive side of battery.
3) Connect negative terminal from wiring harness to negative side of battery.
4) Pass remaining wires through hole in frame below handlebars to route the wires correctly.
5) Lower tank and secure with two screws.
H. Mounting Fairing and Connecting Wiring
1) Reinstall the fairing on the front of the frame and secure with two 14mm bolts. Reconnect stock wiring harness to fairing plugs (two plugs).
2) Connect Morimoto wiring harness to two ballasts and the left hand side light socket (H7 side). This will power your bulbs.
3) Hook up the right hand side light socket (H4) to the two high beam control wires coming from the projectors in parallel. When you activate the high beams, the power will energize the coil and flip up the electromechanical shields.
4) Organize excess wiring and bunch up with zip ties neatly.
5) Test projectors by turning motorcycle on. They should both light up on low beams. Check to make sure high beams work as well. If the high beams do not work, it is possible the polarity of the high beam control wires is backwards.
6) If everything is working correctly, it is time to aim your projectors. If not, check to make sure there is power getting to the Morimoto harness’ relay and that all of your fairing plugs are connected correctly.
7) To aim the projectors, place the motorcycle on a flat surface and move as close to a perpendicular wall as possible. Mark the cutoff line on the low beam with a piece of tape. Move the motorcycle back 25’ and then adjust the height adjustment nut (10mm) until the height of both low-beams is 2.1” below the original tape line. You are done aiming.
8) Reinstall inner fairing panels and mirror boots. Check to make sure no wires are loose, dangling, or kinked.
Bi-Xenon Projector Retrofit on a 2005 Yamaha FZ
The purpose of this tutorial is to guide you through the replacement of the stock 2005 Yamaha FZ6 headlights with a Morimoto Mini H1 Bi-Xenon Projection system. The information presented is specific to this installation; however, many of the steps are similar for other Japanese sport bikes.
Time to complete: 4-8 hours.
Required Materials
Purchased Kit:
Morimoto Bi-Xenon Mini Stage III Kit (H1)
Tools:
Metric Allen Wrench (4mm)
Metric Socket Wrenches (8mm, 10mm, 12mm, 14mm)
Flathead screwdriver
Philips Screwdrivers (#1, #2)
Wire Cutters
Needle nosed pliers
Equipment and Supplies:
Soldering iron and solder
Dremel tool with cone sanding attachment
Paper Towels
All-purpose cleaner
Electrical Tape
Loctite
Double Sided tape
Zip Ties
Oven and oven mitts
A. Removing Front Fairing
1) Using a four mm Allen wrench, remove the right and left inner fairing panels (three bolts each).
2) Turn handlebars full lock to the left, exposing the two 14mm bolts holding the fairing to the frame by the speedometer bracket. Remove these bolts.
3) Disconnect the wiring harness on the left hand side of the fairing (two plugs).
4) Lift and pull front fairing away from the rest of the motorcycle.
B. Extracting Headlight Unit from Fairing
1) Take off windshield by removing the five #2 Philips head screws located below the mirror boots (four) and underneath the front of the headlights (one).
2) Remove the four 10 mm nuts holding the two mirrors to the fairing. Pull off mirrors.
3) Remove two #1 Philips head screws located near mirror mounting holes.
4) Remove two #2 Philips head screws holding speedometer to top of upper fairing.
5) Remove four #2 Philips head screws holding speedometer bracket to fairing. Pull off speedometer bracket and carefully disconnect wiring behind speedometer (two plugs).
6) Unplug stock headlights and remove rubber boots behind stock bulbs on back of headlight unit.
7) Undo clips and remove both stock bulbs.
8) Remove five #2 Philips head screws holding headlight unit to upper fairing.
9) Carefully pull headlight unit out of upper fairin
C. Removing Lens Covers
1) Clean outside of headlight unit with paper towel and spray cleaner.
2) Heat oven to 200 degrees Fahrenheit.
3) Place cleaned headlight unit into oven for 20 minutes.
4) Carefully remove headlight unit using oven mitts.
5) Working quickly but carefully, work a flat head screwdriver around each lens cover, slowly prying cover off while unclipping tabs as you go around.
6) Repeat for other lens cover.
7) Place removed lenses aside, glue-side up.
D. Mounting Projectors
1) Locate the two projector units, along with the two “mini Gatling gun” shrouds.
2) Using the four supplied Philips head screws, mount the shroud to each projector unit.
3) Remove metal bulb holder from back of projector units by removing the three small Philips head screws on the threaded end of the unit.
4) Identify the correct metal adapter plate (H4 or H7) for each projector and test fit it. They may require a little bit of sanding with a Dremel tool to fit correctly.
5) Place the large silicone washer onto the end of the projector, then install it through the front of the reflector.
6) Place the small silicone washer onto the threads of the projector behind the reflector, followed by the adapter plate.
7) Apply Loctite to metal retaining nut, and carefully begin threading it onto the back of the projector.
8) As the retaining nut begins to tighten (needle nose pliers fit it perfectly and act as a makeshift wrench), start putting pressure onto the front lens of the projector, pressing it into the reflector housing and compressing the silicone washers as you continue tightening the retaining nut.
9) Mounting of the projectors is now complete. Clean the lens and reflector and rid the housing of dust and debris.
E. Re-installation of Lens Covers
1) Place completed reflector unit and two lens covers back into the 200 degree oven for about 15 minutes.
2) Working quickly, press the lens covers back into place, making sure all clips are re-attached; allow to cool for several minutes while keeping pressure on the lenses
3) Re-install metal bulb holder to back of projector units using the three small Philips head screws.
4) Carefully remove protective case and foam from HID bulbs and install bulbs into each projector (taking care to not touch the glass with your fingers).
5) Using supplied spring clip, secure each bulb into its projector.
F. Re-assembly of Front Fairing
1) Mount headlight unit back into front fairing with five screws.
2) Re-install rubber boots on back of HID bulb.
3) Re-install speedometer mount (connecting wiring harness), mirrors, and windshield.
4) Mount the ballasts with double sided tape on the inside of the fairings, or use desired method of attachment.
5) Connect Bulbs to ballasts.
G. Connecting Wire Harness to Battery
1) Lift up gas tank to expose battery by removing the two screws at the front of the tank and pivoting it upwards (A piece of string can be used to hold it from falling down).
2) Connect positive terminal from wiring harness to positive side of battery.
3) Connect negative terminal from wiring harness to negative side of battery.
4) Pass remaining wires through hole in frame below handlebars to route the wires correctly.
5) Lower tank and secure with two screws.
H. Mounting Fairing and Connecting Wiring
1) Reinstall the fairing on the front of the frame and secure with two 14mm bolts. Reconnect stock wiring harness to fairing plugs (two plugs).
2) Connect Morimoto wiring harness to two ballasts and the left hand side light socket (H7 side). This will power your bulbs.
3) Hook up the right hand side light socket (H4) to the two high beam control wires coming from the projectors in parallel. When you activate the high beams, the power will energize the coil and flip up the electromechanical shields.
4) Organize excess wiring and bunch up with zip ties neatly.
5) Test projectors by turning motorcycle on. They should both light up on low beams. Check to make sure high beams work as well. If the high beams do not work, it is possible the polarity of the high beam control wires is backwards.
6) If everything is working correctly, it is time to aim your projectors. If not, check to make sure there is power getting to the Morimoto harness’ relay and that all of your fairing plugs are connected correctly.
7) To aim the projectors, place the motorcycle on a flat surface and move as close to a perpendicular wall as possible. Mark the cutoff line on the low beam with a piece of tape. Move the motorcycle back 25’ and then adjust the height adjustment nut (10mm) until the height of both low-beams is 2.1” below the original tape line. You are done aiming.
8) Reinstall inner fairing panels and mirror boots. Check to make sure no wires are loose, dangling, or kinked.
... allhough... i have 2 questions 
