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Driving lights on the Stelvio (finally!)

Discussion in 'Stelvio Chat & Tech' started by John in PA, Mar 22, 2009.

  1. John in PA

    John in PA Cruisin' Guzzisti GT Contributor

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    Well, I finally finished my installation of the PIAA 1100x dichroic driving lights on the Stelvio. I used the on-board foglight switch and circuitry to control and feed the lamps. I ended up cutting off the stock plugs on the *short* wires up inside the right and left front fairing and using red Posii-locks to make 6 inch extensions for the wires. I had purchased the posi-locks and some very nice waterproof two-pole connectors from Eastern Beaver. I removed the stock PIAA plugs from the lights (unnecessary as I found out later as Eastern Beaver also sells the PIAA compatible connectors, so that step would NOT be necessary. They might even have a small plug that fits up to the stock foglight wire plugs, so stock connector could remain in place, though you would still have to make a short extension pigtail)

    I had wrestled with the decision of where/how to mount the lights. Originally I was going to use a nice mounting bracket machined and black anodized from aluminum that PIAA offers for 1" bars. Bought a set, tried several possible mount configurations, but was dissatisfied with the various options. It seemed that lights would either be exposed to damage in the event of a tipover (not that THAT could happen), or else wires or lamps would be a bit closer than comfortable to exhaust header heat. I also would have needed to custom make some machined aluminum blocks to mount as I had purchased the auto set instead of the powersports set (half the price, same lights and harness, ABS mounting brackets instead of stamped steel) I elected to mount on the underside front of the fairing.

    Result: lights are up high for visibility, don't stick out to the sides in case of mischief/operator error, short wire run to power source, no heat issues, and no bracket fabrication. They obviously look "added-on", but then so do lights dangling off the crash bars, and utility-over-beauty seems to be the custom with adventure tourers anyhow. They mount with one 3/8" buttonhead stainless bolt 1" long, neoprene 1.5" washer inside and out for increased friction to resist turning. Stainless 1.5" fenderwasher and a nylock nut on the inside of the fairing, and a standard stainless washer on the outside between bolt head and light bracket.

    Here are a couple pics of the finished product. I haven't tried them at night, but had the same lights on the Quota, and now on a Can-Am Spyder, and they really turn night into day!! Big even flood of light over 2-3 lanes wide, and about 300 yards up the road.

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    Amazon has a good price on the lights, around $150 if I recall.
     
  2. Moz

    Moz Cruisin' Guzzisti

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    nice job.
    end result is good lighting that will survive riding and a tip-over - can't complain about that ;)
     
  3. loftyjohn

    loftyjohn Cruisin' Guzzisti

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    Hi John

    Bloodly nice job:)

    Any chance of some out and about at night photo's?
    Would be great to see them in action:)



    Loftyjohn
     
  4. Wonder B

    Wonder B Cruisin' Guzzisti

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    Very nice indeed... would love to see the improvement... How much did all of this cost you?
     
  5. nomad

    nomad Tuned and Synch'ed

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    this is what my lights look like

    [​IMG]

    [​IMG]
     
  6. John in PA

    John in PA Cruisin' Guzzisti GT Contributor

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    OK, Here's a shopping list:

    1 set PIAA 1100X Driving lamp set (#1192) $146.03 (Amazon--free shipping) http://www.amazon.com/PIAA-1192-Pla..._1?ie=UTF8&s=automotive&qid=1237892091&sr=8-1

    4 Posi-locks--red (or 2 original style plugs to match guzzi OEM from Eastern Beaver)
    2 2-pole waterproof plugs (or PIAA plugs from Eastern Beaver)
    4 1.5" neoprene washers
    2 3/8"x1" Stainless buttonhead bolts (allen-type)
    2 3/8 Stainless washers
    2 1.5" stainless fender washers 3/8" hole
    2 3/8" stainless nylock nuts
    12-18" two-lead automotive wire, 16 or 18ga
    1 20A relay for the empty slot in the Guzzi relay box inside the right front fairing Pyro Dan's work great)
    4 nylon zip ties


    Wiring option: The PIAA set comes with a complete wiring harness, relay, LED lighted switch. You only have to do the wiring if you want to use the circuitry already on the bike for accessory lights, which gives a neat little ICON on the dash when the lights are lit, and avoids adding clutter to the right handlebar control by adding yet another switch.

    PIAA connectors: http://easternbeaver.com/Main/Elec__Products/Connectors/312_Connectors/312_connectors.html
    Use the 2P connectors

    Guzzi OEM connectors: http://easternbeaver.com/Main/Elec__Products/Connectors/110_Connectors/110_connectors.html
    Use the 2 position .110 connectors

    I only did the posilocks and new waterproof connectors 'cause I didn't see the .110 and PIAA connectors on the site till the job was about done!!

    A 6" pigtail extension plus plugs will about do it on each side


    Mounting on the bike:
    Enlarge the hole in the light mounting bracket to 3/8" and reverse the brackets on the lights. Otherwise you can't access the socket head to tighten. Or use a hex head bolt instead, there's just barely room to get a wrench in if you do.

    Locate and drill pilot holes in underside of fairing, then carefully enlarge to 3/8"

    Fastener order from the outside: Bolt head, flat washer, light bracket,neoprene washer, fairing, neoprene washer, fender washer, nylock nut.
    There's barely room to get a finger inside the fairing to get a start on the nut. I poked an allen wrench up through the hole in the fairing and stacked/aligned the inside fasteners on it, then got a finger inside and started the bolt/washer stack in the threads before adding the light bracket.(the light bracket is in two pieces, and can be split apart and applied after the bolt is started. I discovered this method after many tries and extensive exploration of my vocabulary of expletives. Once tried this way, it was easy.)
     
  7. Ray R

    Ray R Cruisin' Guzzisti

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    Thank you for posting the link for the Guzzi OEM wire connectors. I've tried to find those locally, but it seems everyone I call is clueless. No one carries Sumitomo or they don't know any connector by a .110 name. So I'll have to wait for them to ship from eagerbeaver. If nothing else, owning Guzzi's has taught me patience.

    I'm mounting the lumalink fork mounts with trail tech (eclipse) HID lights.
     
  8. Forseti

    Forseti Cruisin' Guzzisti

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    I e-mailed pyrodan to get shipping info .. He says his relays do not fit in the Stelvio relay socket. :dry:
    Did you need to get a socket for it from somewhere else?
     
  9. WayneOrwig

    WayneOrwig GT Reference

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    He is mistaken. I plugged one of his relays that I ought for my EV into my Stelvio driving light socket. His relay may not be correct for the other relays in the bike, but it is correct for the driving lights,
     
  10. Mike.C

    Mike.C GT Reference

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    Nice install John.

    Looking at the first pic, I can see why the Aus red tape people don't like the position of the indicators - they sure would be lost in the headlight. The position of the spotties probably won't help, but I recon that it doesn't matter as the cage in front I can see avoid and anyway he/she probably won't be looking at my indicators anyway.
     
  11. Bluntly

    Bluntly Tuned and Synch'ed

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    Very nice set up, definitely in a safer place than the MG fitting on my NTX. :roll:
     

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