edit (7/30/10): well, after having this thread posted for quite some time, somebody figured out how to do what i couldn't figure out - get the bulb wire harness connections off. if you're looking to not splice the bulbs themselves, then change the "wiring/cutting/splicing portion" of the install to
THIS and then carry on with what i've got. good luck either way - b/c it aint hard, but it aint easy. just tedious.
well, after much debating, and waiting for the right time to snap pics along the way, i'm going to go ahead and elaborate on
Zac's awesome "how to install HID" thread. this thread will explain/show you how to wire up your housing using the stock location/harness and other than a little solder/heat shrink... it's a piece of cake, imo.
first start with zac's thread, and follow those until you've got the headlight housing off. i placed mine on a soft towel on my shop bench with the windscreen part facing DOWN (you'll be working on it upside down... it's easier that way). ONE MAJOR DIFFERENCE between how he did it, and how i did/do it, is i leave the harness plugged onto/into the housing, and simply unplug the main harnesses from the bike. either way will work... but my pictures have the harness still on the housing.
i start by cutting the useless connectors off the supplied "plugNplay" wiring unit and pull the wires out of that big grommet that they're wired through. you'll also pull the bulb wires through once you cut them, but that's later on.
this is with the dustcaps off and the stock bulbs removed. this is easy enough, so i didn't snap any pics along the way. if you can't do this, you're already screwed.
notice the stock wiring harness in the grommet above each hole... clip those wires, and pull them out... the blue side you need, the other side you don't.
install the new bulbs, and reattach the screws/spring that holds it in place.
you're going to have to cut these bulb power wires in order to feed them through the stock grommet. go ahead and pull that big grommet off those wires... you won't need it anymore.
cut them NO LESS THAN 2" from the bulb... otherwise, it's too hard to work with.
be sure to think about which way will be out, and put the big plugs on THAT side... i used a mini-needle nose pliar to pull the wire through the grommet. works like a champ. once you're done putting the grommet back in, add your heat shrink to one side (prolly easier if you do it on the bulb side of the splice), solder them back together, and then move the shrink up over the splice and heat her up. i always pull ALL THE EXTRA wire into the housing for this part b/c you'll need the extra play in the wire. once you're done putting the heat shrink on it, you can pull the excess back out through the grommet. and now you're now done with the bulbs. put the dust caps back on at this point to protect your hard work so far.
(fyi... i use 3/16" heat shrink for a solder, and 1/4" for a butt-splice)
now then, the blue harness that was originally in the stock grommet will now be soldered to the power wire that you snipped first. same story... solder/heatshrink... here's what you've got.
this is what it looks like once everything is ready to mount back up to the bike. after you get her mounted up, you simply plug the power supply (blue harnessed one) into the ballast, and the ballast back into the two little plugs that go to the bulbs.
this next part is tricky... odds are you, you crossed the positive/negative somewhere along the lines. this isnt' the end of the world. one/both of your lights don't fire up, simply unplug the ballast side of the blue harness, and switch the pins. take a tiny screw driver and look into the harness, and you'll see little bitty tabs next to the pins. press those tabs, and pull the wire out from the bottom. switch em, and you should be good to go. i think there's a good how to on R6messagenet.com about removing harness pins.
finished... and not warmed up yet 10000k HIDs in ASTEBBS bike. yeah behhbbb!
anyhow, i hope this helps ease some of y'all's concerns about wiring up a set of HIDs... like of told MANY of y'all via PMs, it's not hard, it's just a little tedious and time consuming. but when you do it right, it turns out nice and they look CLEAN!!
good luck... i know anybody can do this.
fwiw... a butt splice can be substituted for the solder if you want. just be sure to heat shrink it to keep the color from showing.
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