Auxilliary Light Install KGT

[Semper_Fi]

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[Semper_Fi]

The following DIY project will show how to install a set of auxilliary lights on a KGT, specifically a 2009 KGT 1300.

NOTE - please check your local laws to understand the requirements associated with Auxilliary lighting.

For example, in Massachusetts, it is a state law requirement that if the auxilliary lights are on, they are automatically turned off when the Hi-Beam on the main headlight system is activated.

Instructions for shutting off the auxilliary lights when the high-beam is turned on are included in the DIY

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PROJECT OVERVIEW

The premise of this DIY is that I wanted to have auxillary lights on the bike mounted under the oil cooler area as in the RT, and I did not want to mount them on the caliper as others have. After some searching and vendor calls I realized they do not make mounts for under the cowl for the newer KGT.

However I was provided a link for Jimmy Mounts from BMW Denver. These mounts are made specifically for the PIAA* Style lights so I ordered them. They mount under the rear view mirrors. I checked them out and they looked pretty good (to me) so they were ordered.

* although made for the PIAA light it appears they will accept any vertically mounted style light

Here is the link

The project consists of 3 to 4 seperate steps.

Step one - prepping and mounting the Jimmy mounts

Step two - mount the lights to the Jimmy mounts

Step three - lay out and install the wiring harness**

Step four - modify wiring to support High Beam shut off of aux lights - check your local law requirements


** Please note that using the Jimmy mounts and the amount of excess wiring provided in the harness you WILL have to cut the harness and connectors in various places - this will obviously void any warranty provided by PIAA so please be fully cogninzant of this aspect of the install if you plan to do it.

[Semper_Fi]

Shown below are the Jimmy mounts, their hardware and instruction sheet.

they are power coated black and are very robust - suitably able to support the PIAA Light

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The lights and their accompanying parts

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You need to get the bike to a usable access position to work on.

The easiest is removing all the plastic and windshield to be able to properly mount, route and install the various items.

This link shows how you how to remove all the plastic

This link shows how to remove the windshield - please note you can stop when you get to post # 15 on this one

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Shown here is the sequence of hardware that will be used to mount the Jimmy Mount to the bike.

From left, it will be a Hex screw, with a washer, the plastic sleeve slides on next and then that hole combination is put into the mounting hole and then the hex bolt is threaded onto the bike supporting the mount.

The hex bolt has a 5mm head.

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Things to note - the first

Check for flash on the plastic sleeve and remove it - this will provide a better fit

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Second

The bottom of the Jimmy Mount will flush mount to the side of the front cowl - even though I do not plan to remove the mounts I did not want to have the area damaged by the permanent contact, so I added some rubberized tape onto the mounting area to protect the painted surface that will be in contact here.

Optional - not required

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Shown is the mirror removed and how it would mate to the mount for install.

DO NOT INSTALL - because you need to mount the lights first and route the light harness thru the mount before putting the mirror(s) back onto the bike.

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OK - the mount is preped and we are ready to install the light onto the mount.

The instructions call out that the small hole on the side of the mount is for the wire harness.

As you can see PIAA provides some nice connectors that in no way will fit thru the hole.

Here you have to choices:

1 - you can leave the connectors intact and wire the lights with the harness outside of the mount

2 - you can cut off the connectors and run the light wires thru the hole as provided.


I went with option 2 because I wanted a clean look - but be advised any modification to the harness will void your warranty for the PIAA product, and probably any product you use.

[Semper_Fi]

Since I am going to cut off the connector, I wanted to identify/maintain the same wire polarities to the lights.

I checked both connectors and if you pull them out straight you will note that one wire will be slightly longer (green arrow) because there was more slack, in my case, the longer wire in each connector is associated to the ground side of the wiring.

So the shorter wire is postive, the longer is negative and it was the same for the other light.

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I put a small piece of shrink tubing to identify the postive line and then did the same for the other light.

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Displayed below is the assortment of hardware to mount the lights, depicted is the order of their assembly (Top to bottom)

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OPTIONAL STEP

The hardware supplied came with a standard nut, I did not think that was robust enough and replaced it with an M4 Nylock style to ensure that it would not come loose.