I looked through the directions ,it has like 19 steps.It may be easy but Im a little dense at times.
From there site.
. On your original light, unscrew the 2 headlamp screws, remove headlamp and disconnect both main socket and park light plug. Unbolt main lamp shell using 12mm spanner (bolts horizontally) and feed wires out of the back through hole.
1B. Remove existing bolts from speedo and fit bracket supplied. 90 deg end uppermost (see photo below) bolt into position with nyloc nuts and 6mm bolts supplied.
2. Using a sharp knife carefully cut the main loom insulation back 1 inch to split the loom so that the white main plug is on the left and the black plug is on the right, re-tape with insulation supplied.
3. Crimp on blue 'Power take off' connector to larger green wire on white main plug (on left side)
4. On R/H lamp crimp another 'Power take off ' connector to the black wire (off the back of the main standard light socket)
5. On R/H lamp crimp the last 'Power take off ' connector to the blue with white tracer wire also at the back of the main standard light socket.
6. Separate connector plugs white and black, feed the large grommets down both wire looms (white and black connector plugs)
7. Loosely bolt on new headlight bracket so it will not move unless small amount of force is applied. (So it won’t flap about while mounting things)
8. Mount new Thunderbike headlight shells to brackets, loosely as above. Make sure that the holes at the rear are both inner most.
9. Feed white connector plugs and small Speedo light plug (black) through left light housing Feed from back into cavity. Note connector blocks are a tight fit through housing. But will go with out forcing if feed through a correct angles when plugs separated. Fit grommet into shell.
10. Feed black connector plugs into right housing as per left and fit grommet.
11. Feeding of the new Thunderbike “twin headlamp†loom. Feed the non relay end of the loom through the left shell from the front, and across to the back of the right lamp. Feed through into right shell. (You should now have the relay in the left shell)
12. staying with left shell, connect brown-green wire (short wire off relay) to connector that was fitted earlier. (Green wire on white connector plug) this is the power feed to relay.
13. Connect left light socket to lamp. Fit high beam indicator lamp to inside of shell, by blue lens. NOTE factory park lamp wires not used. Gently tuck wires and relay into shell and about reflector as inserting lamp. Fit surround and secure screw.
14. Right lamp, connect black wire to connector fitted earlier (on back of factory lamp socket) black to black.
15. Right lamp, connect blue wire to connector fitted earlier (on back of factory lamp socket) blue to blue-white.
16. Connect right light socket to lamp. Fit high beam indicator lamp to inside of shell, by blue lens. Gently tuck wires into shell and about reflector as inserting lamp. Fit surround and secure screw.
17. Test lights Hi and Low. Adjust lights by setting up in front of a wall, with tyre touching mark on wall position were the beam hits, back bike away at 90 deg. At 3 meters check alignment pattern again on wall. Should drop approx 50-mm (depending on country of residence) @ 3mtrs. And be centered. NOTE there is 3 ways of adjustment in the brackets.
18. Enjoy brighter, cool looking lights!
Last edited by smaug; 04/14/2010 8:51 PM.
