My Baja designs SQUADRON LED light install

[stevepsd]

I bought these from Jaxon's great group buy earlier this month and finally have them installed (*almost*) and thought I would create a separate thread on install.

The lights each have 4 LED driven elements, 2 are SPOT beams and 2 are wide angle beams. They draw 44 watts on full power each (there are 2 lights) and on high I swear they will melt anything in their beam. Since they re so bright, the group buy came with a programmable dimmer module, with RF remote control, so you can program the lights to come on at a reduced brightness and have the option to go to full power when you flip on the high beams.

Since I wanted to control when the lights are on, I added a PIAA waterproof motorcycle switch (PIAA part # 74034) http://www.amazon.com/PIAA-74034-Switch-Powersport-Harness/dp/B003D5E8DY/ref=sr_1_1?s=automotive&ie=UTF8&qid=1338168273&sr=1-1

Here is the info on them: http://www.bajadesigns.com/ProductDetail/660057_Squadron-Adventure-Bike-Kit

Mounting the lights:

I just started fooling around with mounting the Squadron lights and noticed that the mounts 'almost' line up with the upper mounting hole on the bike's built-in mount, so I decided to slightly modify the 'U' brackets to have them fit correctly. Only one side of each bracket has to be modified. Mounted the bracket to the bike with a 6mm counter-sunk screw (works great since the hole in the bracket is 8mm and the counter-sunk head centers the bracket with the mounting hole on the bike).

They are now up as far as possible and just about touching the bottom of the headlight housing. I will have to see how they beam pattern looks tonight (I have not wired them in yet, so I'll have to improvise!) to make sure that I can get enough vertical adjustment. If they need horizontal adjustment I'll have to work on that as there is no adjustment in the mounting brackets (as least as they come from Baja Designs - I can fix that!).

I also have almost 7.5" of clearance between the fender and the bottom of the lights.

 

[stevepsd]

Now on to the electrical install:

I needed to find a place to mount the large dimmer module (it's like 2.5" square). Most mounted it in the cubby where the so-called tool kit resides but I have tentative plans to possibly mount a PowerCommander and Autotune module and even those will fit with the dimmer, it was a bit to congested for me, so I found a great place...right next to the voltage regulator. Used the provided all-weather industrial velcro fastener to secure it. But first I had to connector-ize the dimmer (the wiring provided is generic - so you have to roll-your-own).

I was able to snake the cables for the lights (they have nice weatherproof connectors) to come out on the right side of the bike, just above all the OEM relays. I connected the mating connector directly to the dimmer module. Trimmed the cable length so it is correct.

I also picked up the yellow 'hi-beam' by tapping in the stock connector (located in the bundle of wires also above the OEM relays) and putting a short length of wire and a weatherproof bullet connector on it. Put the mating connector on the dimmer and trimmed to length.

Now i just needed to run power for the dimmer (when then goes to the lights). I could have easily wired them up to my FZ-1 fuzeblock, but Yamaha provided us with a nice connector just for this purpose, on it's own 20AMP circuit, with a switched power source as well to make connecting a relay easy. Yamaha even provides the mating connector, but without the pins. A quick order to Eastern Beaver and had the pins (Easter Beaver is a great outfit - I think they have all the different/weird connectors used on most motorcycles).

So I used the stock wiring to provide power, switched power and ground.

Since I wanted to add a independent switch to control when the lights were actually on (at a preset level when on low-beam and at full-power when on hi-beams) I needed to add a switch controlled relay. The PIAA 74034 waterproof switch is just the ticket. It has a dual color LED indicator light that tells you when your lights are on or off. Since I really did not need a indicator to tell me when they are off (I always get confused - is Green ON or is RED on?) a simple switching of the non ground leads (there are 3 leads on this switch) and a RED indicator comes on when the lights are on. Easy.

I mounted the relay (a Bosch 30 Amp with mounting tab) onto the un-threaded post next to the battery (this is where the Yamaha fog light kit mounts their relay as well). A 6mmx1.0mm tap and its ready.

I made a small wiring harness that goes the the relay connector and has the 3 other connectors on it as well - the 3-wire triangle OEM lighting connector (power, switched power and ground), a 3-wire Molex connector for the PIAA switch and a 2 wire weatherproof connector for power & ground for the dimmer/lights.

In the end I had to obtain the following:

1 - 30A Bosch relay with mounting tab (you can use the Baja Designs provided relay if you mount your relay differently)
2 - Male pins for the OEM fog light connector (3 pins)
3 - A 2 conductor connector for the dimmer box power & ground
4 - A 3 conductor connector for the PIAA switch
5 - the PIAA #74034 switch

I reused as much of the Baja Designs provided wiring and connectors as possible: the bullet connector for the high-beam sense, the connectors for the relay socket, the two weatherproof light connectors and most of the wire.

Here is a schematic and some pics:

 

[stevepsd]

When I first tested out these lights, they were overpowering. Even though these are a combo SPOT/Driving/Fog type light, there was a OVERPOWERING center spot that was so bright I was afraid it would catch the atmosphere on fire....well not really, but almost!

So I needed to slightly adjust the mounting brackets to get some side-to-side adjustment. I ended up taking the brackets off and slightly re-bend them to slightly move the lights to the side. Sorry, no pics of that but it was simple. I ended up with the lights splayed out about 5/16". The light pattern was great. I'll try and take some pics of the lights at night, but suffice to say light up the road of at least 1/2 mile and the beam is very wide near the bike. The best lights I have seen.

 

[sail2xxs]

Awesome, informative post! I've been holding off on installing the lights because I suck at anything electrical, and was hoping someone would post a well-documented job. ::012::

Thanks!

Chris

 

[jajpko]

Outstanding job!!!! The lights look fantastic.. ::008::

 

[tomatocity]

I like them.

 

[~TABASCO~]

I agree... these things are nutty bright ! I LOVE'EM !!!!! Good job on your install ! ::008::

 

[Tremor38]

When I first tested out these lights, they were overpowering. Even though these are a combo SPOT/Driving/Fog type light, there was a OVERPOWERING center spot that was so bright I was afraid it would catch the atmosphere on fire....well not really, but almost!

So I needed to slightly adjust the mounting brackets to get some side-to-side adjustment. I ended up taking the brackets off and slightly re-bend them to slightly move the lights to the side. Sorry, no pics of that but it was simple. I ended up with the lights splayed out about 5/16". The light pattern was great. I'll try and take some pics of the lights at night, but suffice to say light up the road of at least 1/2 mile and the beam is very wide near the bike. The best lights I have seen.

Hi Steve.

I did the same thing with the brackets. The light now has a better spread, but it's still on the verge of 'overpowering' which I supposed is a good thing. Any reason for not opting to use the relay that came with the lights? Was it too big for you liking? Thanks.

 

[stevepsd]

Hi Steve.
Any reason for not opting to use the relay that came with the lights? Was it too big for you liking? Thanks.

The relay that came with the kit is perfectly fine, but it did not have a mounting tab so i could not bolt it down on the post next to the battery (thats the location for the factory foglight relay, btw). I could have used the other realy and just zip-tied it to the harness but since I have a bag of these relays, the choice was easy. Just being a bit picky.

 

[Tremor38]

The relay that came with the kit is perfectly fine, but it did not have a mounting tab so i could not bolt it down on the post next to the battery (thats the location for the factory foglight relay, btw). I could have used the other realy and just zip-tied it to the harness but since I have a bag of these relays, the choice was easy. Just being a bit picky.

I see. I opted to use the EB PC-1 fuze box for the switched power, since I already have the relay for the PC-1 in the spot you mention. Could have probably bought one of the slim profile 30A relays sold over here and mounted back to back with the EB relay I suppose. Haven't come across the need to secure the squadrons while in high beam yet, but may eventually decide to go that route if I find it beneficial in enough situations.

 

[stevepsd]

....... Haven't come across the need to secure the squadrons while in high beam yet, but may eventually decide to go that route if I find it beneficial in enough situations.

Just to be clear, the switch I added enables ME to control when the Squadron lights come on, irrespective if the headlights are on either low beam or high beam.

I preset the dimmer module to around 40% brightness, so if I turn the Squadron lights on (with my switch) when the bikes headlights are on low beam, the Squadron lights will come on at this 40% brightness (used to fill the stock low beam pattern, but not blind oncoming traffic).

If I turn the Squadron lights on when the bike is on high-beam, then the Squadron lights will come on at full intensity.

 

[avc8130]

What does the factory "aux light" connector do?

I guess it doesn't have high and low feeds?

ac

 

[stevepsd]

What does the factory "aux light" connector do?

I guess it doesn't have high and low feeds?

ac

The factory aux light connector is on it's own circuit. The connector provides a dedicated unswitched power source, a switched power source (hot only when the ignition is on - actually the headlights have to be on ) and a ground. There is no high beam/low beam feed - well....the switched power lead is only active when the headlights are on...

I used this connector to provide power to the aux lights, and used the switched power source to control the relay..which in turn does not allow the aux lights to come on when the bike is off.

 

[avc8130]

The factory aux light connector is on it's own circuit. The connector provides a dedicated unswitched power source, a switched power source (hot only when the ignition is on - actually the headlights have to be on) and a ground. There is no high beam/low beam feed - well....the switched power lead is only active when the headlights are on...

I used this connector to provide power to the aux lights, and used the switched power source to control the relay..which in turn does not allow the aux lights to come on when the bike is off.

Ah, so Yamaha intended the factory option lights to be on any time the headlights are on. Got it.

ac

 

[avc8130]

I see Jaxon is running another group buy over on ADVRider. Do I NEED to get in on this?

A buddy picked up a set of the Denalis from Twisted Throttle. I'm not going to lie. I am underwhelmed with what they accomplish.

Are the Baja's the "cat's meow"?

ac

 

[Tremor38]

Re: Re: My Baja designs SQUADRON LED light install

Just to be clear, the switch I added enables ME to control when the Squadron lights come on, irrespective if the headlights are on either low beam or high beam.

I preset the dimmer module to around 40% brightness, so if I turn the Squadron lights on (with my switch) when the bikes headlights are on low beam, the Squadron lights will come on at this 40% brightness (used to fill the stock low beam pattern, but not blind oncoming traffic).

If I turn the Squadron lights on when the bike is on high-beam, then the Squadron lights will come on at full intensity.

Ummm, already understood, because your schematic shows you controlling power to the dimmer module. With the dimmer module alone, you can shut off the lights with the power button on the key fob while in low beam, and when you turn power back on, your previous dimmer setting is retained. SOOOoo, you've added the ability to secure the lights while in high beam and conslolidated the ability to control the power, regardless of whether you are in low or high beam, into one switch. I can comprehend this....no worries )

Sent from my F-05D using Tapatalk 2

 

[stevepsd]

I wired it this way as I just didn't want to deal with the key fob. I used it to set the low beam intensity and will probably not use it again.

 

[Tremor38]

I wired it this way as I just didn't want to deal with the key fob. I used it to set the low beam intensity and will probably not use it again.

Good move. Another possible benefit of the way you have them wired is that you can give somebody a good comparson between high beam only and high beam with the Baja lights if they are considering a purchase. Also, I'm sure you can find your switch much easier than the key fob's power button while wearing gloves. Right now my key fob is held onto the brake reservoir with two-sided tape. I seldom feel the need to secure the lights unless I have to leave the key on for maintenance purposes, so I'm usually stopped with gloves off, and I haven't changed the dimmer since the first time I set it.

 

[Ridetherock]

Good stuff. I just picked up my new super ten this weekend and will be installing my lights the next days have off

 

[stevepsd]

I see Jaxon is running another group buy over on ADVRider. Do I NEED to get in on this?

A buddy picked up a set of the Denalis from Twisted Throttle. I'm not going to lie. I am underwhelmed with what they accomplish.

Are the Baja's the "cat's meow"?

ac

If you ride at night, you need these lights. I am not kidding when I say I thought they would set the air on fire when running at full-intensity. They are bright, and combine a spot /driving light and fog light beams in one unit. They are amazing. Period.

Just for comparison, the Denali D2's put out a claimed 860 lumens. The Squadron lights put out 3600 lumens each....