PIAA Light Installation
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PIAA Light Installation

(Make sure you scroll to the bottom to see the update from 12.30.2004)

This pictures shows the front of the bike disassembled. 

You can see the voltage reducer on the right side and the relay for the lights on the left.

Though fuzzy... this pictures shows the location of the switch for the lights. 

I pulled that little plug out of the handlebar unit and sanded a flat spot where I could adhere the switch.

These pictures show the location of the switch for the voltage reducer.  

When it's off, the lights are at 55 watts; when on, the wattage is reduced to 35 watts.

This shows the raw cut for the bracket.

I cut it from 1-1/2"X1-1/2" angled aluminum, then I painted it with glossy black paint.

For the back, I cut another piece of angled aluminum to sandwich the fender.  This piece goes on the inside, and the light bracket goes on the outside of the fender.

The pictures below are different shots and angles of the installation:

IMG_1455.jpg (130268 bytes) IMG_1461.jpg (106538 bytes) IMG_1465.jpg (98889 bytes)

Update: 12.29.2004

I had an email exchange with one of the guys from the Chain Gang.  The relevant information is posted below (read bottom up):

----- Original Message -----
From: bill
Sent: Wednesday, December 29, 2004 9:51 AM
Subject: Re: Question about your f650 that is on the f650 board

Will you be able to send me both of them?
I will cut you a piece 22" long.  From this piece, you can cut the 18" light bar and the 3-15/16" backer bracket.  When you make the cut, the width of the blade will take away the 1/16".  I also drew you a picture (attached) of how to cut the metal.

Make the first cut as indicated it the drawing so you have the entire length of bar to hold onto while you make your cut.  Do not cut too far though... stop exactly where you will cut the lightbar to length.

On a 1-10 rating how difficult was it to wire this up?

I'd say it is a pretty simple install.  The hard part getting everything mounted and hidden.  There is so little room... that's the challenge.  The directions for both products are very clear.  Read them twice before you do anything.  If I were to rate it given all factors involved, I would say it is a 4 or 5... but I am quite skilled at mechanical stuff.  But, it really is pretty simple.

One other thing I did was to go behind the dash where the LED for the volt meter mounts and glue it in place with plastic epoxy.  The LED doesn't want to stay in there all that well... and with all of the vibration... you get the idea.

Also, make sure to really think about where everything goes.  There really is very limited room.  Remember you have to put the headlight back in there.

And, zip-ties are your best friend.  You can use LARGE zip-ties to hold the components in place.  Just use several along both axes (I am not sure how to spell the plural of "axis"... I think that's it).

And finally, I used two 5/16" (diameter) X 3/4" (long) stainless steel bolts and stainless steel nylon lock nuts to sandwich the brackets between the fender.  The backer bracket acts as the washer.

----- Original Message -----
To: bill
Sent: Wednesday, December 29, 2004 9:51 AM
Subject: Re: Question about your f650 that is on the f650 board


Your the man!!!!!!!!!!

Once again, your set up is exactly what I was looking for.  I love the idea of the volt reducer.  Rather than shutting the lights down you still get some use of them.  I want the lights for more safety reasons so people can see me rather than me seeing them.  I have also installed the Hyperlights.  They were easy and work really well.

I have just ordered everything.  The volt monitor, volt regulator and lights.  I went for the Hella Opix. Series because of the cost.  They should work out well.

I would like to take you up on your offer on the light bracket if that is cool.  I noticed that you used two brackets.  The first is what you connected the lights to and the other was more for bracing the light bracket to the bike.  Will you be able to send me both of them?

If you will supply me with your address I will send you some money for the material as well as the shipping.  Don't be to nice of a guy here with the cost.  Make it worth your time.  You have been really helpful by spoon feeding me the information that you have supplied.

On a 1-10 rating how difficult was it to wire this up?  I have a buddy of
mine that is good with electrical systems that I sure would help if he has
the time.

Bill, thanks again for the help.  I need all I can get.

----- Original Message -----
From: "Bill"
Subject: Re: Question about your f650 that is on the f650 board
Date: Wed, 29 Dec 2004 08:54:01 -0600

Read this: http://f650.com/forums/ShowPost.aspx?PostID=100873
and this: http://www.f650.com/Forums/ShowPost.aspx?PostID=95990

I did similar research...

The bar is 18".  I have some extra if you want me to cut you a piece and mail it to you.  You can have it for free if you send me a few dollars for shipping.

Let me know if you have other questions... I enjoy helping folks willing to do their own work.

 ----- Original Message -----
To: bill
Sent: Wednesday, December 29, 2004 8:20 AM
Subject: Question about your f650 that is on the f650 board

I have been doing some research on putting lights on my 02GSA and then came by your website, which is nice, and you have the set up I would love to copy.  You have the voltage meter as well as the reducer.  I have not seen a reducer before, the only thing dad taught me about electricity was to stay away, so I am interested to see where you got yours?  Did you get the reducer from signal dynamic's also?

Also, how wide did you make your bar to hold the lights?

Thanks you for any of the information that you can share with me.

Update: 12.30.2004

Mounting the lights only to the fender permitted them to vibrate a bit even though they were attached to the fender very close to where the fender bolts onto something more solid.  As a result, the lights would "flicker" up and down as the motorcycle idled or as it went over bumps.  Unacceptable!

To fix this, I fabricated a bracket to go from the location where the fender mounts to the solid metal piece where the forks attach, and I bolted it to the light bar.  Now instead of only being attached to the plastic fender, it is bolted solidly to the bike and there is absolutely no vibration.  Perfect!

Numbering is only to identify pieces; it's not an assembly order.

Though blurry, the following two pictures show the last of the three brackets.  It's the one that fits inside the fender... #6 from the drawing above.  The first picture simply shows the piece cut to length, the second picture is after I grinded some curves in the bracket so it fit perfectly (a Dremel tool and belt sander works well on aluminum).

The two holes in the second picture match up to the two holes in the fender that allows it to be bolted to the motorcycle... #4 from the drawing above.

What's not shown in the photos are the two holes drilled to accommodate the 6mm stainless steel bolts that go through both aluminum brackets and the fender... #5 from the drawing above.  Drilling the holes through the fender is a challenge; an angle drill would have been nice because of the limited space, but it can be done with a slightly over-sized drill bit.  You simply have to be really careful to ensure the spinning drill chuck does not rub against any painted surface.


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