Aux Lights with Switch Install

[Samaha]

I installed a set of Aux lights using an LED wiring harness with a switch.  The install took 90 minutes including adjustment of the lights.

 Project materials and tools:

·         AutoTime 2 Pack 3.5 Inches 25W LED Work Light Flood Spot Combo $57

·         DZG Universal LED Light Wiring Harness Kit with Relay  and On/Off Switch $18

·         20MM X 3MM (~8”) Black Mending Bracket $3

·         2 Washers

·         2 rubber grommets (optional)

·         Heat Shrink Wire Connectors

·         Heat Shrink Crimping Tool

·         Heat Gun

 

Steps

Step 1 – TEST by connecting Wire Harness to lights and Power/or Fuse Box (See Aux Light Install 1).

Step 2 - Appropriately run the wires from power to the lights and switch.  I ran mine underneath the plastic side fairings and zip tied to existing wires.  For the switch, I did the same, going up the fork column to the handlebar; make sure you allow some wiggle room for turning. (See Aux Light Install 2)

Step 3 – Line up the mending bracket to furthest part of the fairing and drill two holes in the plastic.  Ensure there is space to push through a screw by gauging with your finger.    NOTE: If you prefer not to drill into the plastic, you can use the existing holes.  I used the existing holes for the light wires and inserted a rubber grommet on each side. (See Aux Light Install 3a and 3b)

Step 4 – Mount the lights loosely using the included hardware.  Push the screw through the light bracket, mending plate and fairing hole.  On the inside, be sure to use a metal washer between the plastic and lock nut (See Aux Light Install 4)

Step 5 – Use 2 zip ties to further secure the plate by looping through each bracket located directly above the existing holes. (See Aux Light Install 5a and 5b)

Step 6 – Adjust and tighten the lights to the desired angle. (See Aux Light Install 6a, 6b and 6c)

[knyte]

Looks great!!  Thanks for the excellent write-up, you're giving me some ideas...

...still far to clean, though

Edited July 20, 2020 by knyte

[Samaha]

2 minutes ago, knyte said:

Looks great!!  Thanks for the excellent write-up, you're giving me some ideas...

...still far to clean, though

lol, thank you.  happy to add more pics of different angles if you want.

[betoney]

Good job, looks like a clean install.

[WKE002]

Great ! Was checking around youtube, no one actually zoom in on the exact placement bracket as always taken from far... HUH!

That have hold me back on purchasing and DIY myself till am very confident to install. 

[piotrek]

1 hour ago, Samaha said:

Step 5 – Use 2 zip ties to further secure the plate by looping through each bracket located directly above the existing holes.

...do the zip ties need to be there? Is the flat bar secured to just the plastic above it or something more solid?

[Samaha]

19 minutes ago, piotrek said:

...do the zip ties need to be there? Is the flat bar secured to just the plastic above it or something more solid?

Its up to you.  My lights are 1 lb each so i felt more comfortable adding a second layer of support.  Regarding the second part of your question, the lights are attached to the plastic with the flat bar on the outside and a metal washer inside.  The attached pic is a very poor attempt to illustrate.

[piotrek]

The sketch describes it well. The lights look great. Just monitor for the plastic bits coming sloppy or fatigued over time. Consider steel supports that mount up to the framing parts... if available that is.

[betoney]

@Samaha - I agree with @piotrek about possibly needing a steel support.  Grab the front of the light housing and gently move it up and down to see if it moves or the plastic flexes - at all, then imagine hitting a few potholes and see if it is secure enough.  Better safe than sorry.

[Samaha]

thank you.  Fair points.  i will look into a way of supporting it a steel support.  For now the zips dont allow any flex but as stated, it could become fatigued over time. 

[Samaha]

On 7/20/2020 at 9:28 PM, betoney said:

@Samaha - I agree with @piotrek about possibly needing a steel support.  Grab the front of the light housing and gently move it up and down to see if it moves or the plastic flexes - at all, then imagine hitting a few potholes and see if it is secure enough.  Better safe than sorry.

UPDATE: After receiving feedback from this forum, I decided to mount the lights to steel supports on the bike.  I used the following parts:

·         One 12 inch 3/8 threaded rod – used rubber mallet to push through $1.50

·         2 20MM X 3MM (~8”) Black Mending Bracket $6

·         4 3/8 washers 30 cents

·         4 3/8 Lock nuts 60 cents

·         Two  2 inch elbow brackets 60 cents

·         Dual Camera Mount Flash Bracket Extension Bar 10.6'' $10

Step 1- Push the threaded rod through the hollow metal cylinder as shown in Aux Light Install 7 and make sure it’s the same length coming out of each side (approx1.5 inches).  Use (use 3/8 Lock nuts to secure on each side)  

Step 2 – Fasten the mending brackets on each side.  Before you mount the bracket ensure you run the bracket through the bottom of the fairing as shown in Aux Light Install 8.  To Mount the bracket I used 2 washers, then put on the bracket and then secured with another 3/8 locknut as shown in Aux Light Install 8a. 

Step 3 – Attach 2 elbow brackets to each side of the mending plates as shown in Aux Light Install 9.  I drilled some extra holes into the mending bracket to accommodate the holes in the elbow bracket.

Step 4- Attach the Dual Camera Mount Flash Bracket Extension Bar to the top of the elbow brackets and light beneath as shown in Aux Light Install 10.  Remove any slack and tighten everything up.

[piotrek]

Clever re-design. Replace these bolts (each side) and you're golden. 😬

[Salish900]

I'm going to add aux lights sooner than later and appreciate this information. What is meant by Aux light install 10 in each section? Is it only referring to the photos? Or is there some DIY narrative somewhere? 

[Ride365]

Bravo sir......BRAVO, perhaps I could ride up there to PA one of these days and you can she me how it's done?  Love your bike by the way, not sure why some don't like the color of our new 2020 GT's?