The reasons I did the dual bi-xenon setup are:
1. Once you’ve driven with xenon projectors, there’s nothing like it and I wont settle for anything less.
2. The bi-xenon’s allow for instant high beams. With a retro setup in the stock projectors you have to wait for the hi beam bulb to warm up and reach operating temp. Yeah... its not that long of a wait, but when you’re cruising down a dark road, that wait seems like an eternity when your in deer country.
3. With both bi-xenon lights operating, you use 70 watts of power compared to the 120 watts from the stock system.
4. Two lights are better (looking also) than one.
So.......Here’s my HOW-TO for the 2006 Dual HID Bi-Xenon install. You can do it anyway you want, but this is how I did it.
First we have the parts list:
1 Stock headlight housing ($350). I purchased a new one to avoid down time with the bike.
2 MB E55 Bi-Xenon Projectors. Make sure they have the pigtails for the solenoids.
2 Hella ballast with built-in igniters for D2S bulbs.
2 Phillips D2S Bulbs, 4300K.
1 Hella 30 amp relay.
1 30 amp mini fuse holder with fuse.
1 H9 and H11 Bulb. (You’ll cannibalize these to wire into the stock plugs).
The wire to connect all the parts together. I used a Hella wiring kit and then cut it down for my application. It includes the relay and the wiring that are all ready connected together.
OK, lets get started. NOTE: Cleanliness counts during the refit.
Get the headlight housing out of the bike and remove the bulbs and rubber grommets at the rear of the housing. If you bought a new housing then the lights and rubber pieces do not come with it.
Pre-heat the oven to 175 degrees. Once heated, put the housing in for 10 minutes. Don’t get distracted and keep an eye on the heating process. You may have to do this a few times to get both lens covers off. This makes the adhesive holding the lens covers very pliable. You might want to use gloves for this next procedure. Remove the housing after 10 minutes and with a blade screwdriver carefully pry the housing and lens covers apart. NOTE: Do not break off any of the small plastic tabs around the housing lens. Once it starts you can pretty much use your hands to finish. Be careful with the adhesive. It’s very sticky and will get all over everything if you get sloppy. Once the covers are off, let the pieces cool down. This will cause the adhesive to somewhat solidify. Do not scrape out the adhesive as it will be used to put the housings together later. (Others have used a heat gun, if you do, be extremely careful that you don’t melt or distort the plastic housing and housing lens).
Remove the stock projectors from the housing and set aside. You will need 2 of the plastic pieces from each light.
The MB E55 projectors come with a little too much metal that you will have to trim off. A dremel tool with a reinforced cutoff wheel works great for this. If you use the Hella ballast with the internal igniters you can trim off all metal brackets around where the bulb goes in. It will give you more room for aiming adjustment in the rear of the housing.