Lupus Lights LL001 – 2014 Yamaha FZ-09 Integrated Tail Light Installation Manual Rev 2.
TABLE OF CONTENTS Tools You Will Need Page 3 Section 1: Removing Stock Tail Light from Motorcycle Page 4 Section 2: Removing Stock LED PCB from Tail Light Page 12 Section 3: Adding Lupus Lights PCB to the Tail Light Page 19 Section 4: Placing Modified Tail Light on Motorcycle Page 25 General Disclaimer Page 32 Limitation of Liability Page 32 Legality of Product Use Page 32 Warranty and Returns Page 32
Tools You Will Need -Phillips Screwdriver -4mm Allen Key -10mm socket -8mm socket -Socket wrench to drive both sockets mentioned above -Flat Head Screwdriver -Needle-nose plier -Preheated Oven -Oven-safe non-metallic surface to place tail light assembly on (wood, silicon baking sheet, etc) -Camera (to take before and after pictures and send to us so we can post them on our website) -Sealant (refer to the sealing procedure on page 7 for possible options)
Section 1: Removing Stock Tail Light from Motorcycle Step 1: Remove the seat Step 2: Before dealing with electricity make sure you disconnect the battery! ☠
Step 3: Disconnect the tail light signal connectors from the stock lamps (grey and black connectors shown below)
Step 4: Remove (2) 10mm bolts
Step 5: Remove (2) 4mm Allen key bolts Step 6: Press in (2) push clips with 4mm Allen key to release then pull out the entire through the bottom
Step 7: Pull the two pieces of plastic apart on the rear tail on both sides to give room to access (4) 8mm bolts on each side
Step 8: Remove (4) 8mm bolts to remove seat lock bracket Step 9: Remove the seat lock bracket
Step 10: Remove (2) 10mm nuts holding tail light assembly bracket on Step 11: Carefully remove the bracket so that disconnecting the white connector is easier.
Step 12: Unplug white connectors (TIP: Depress tab with flathead screwdriver and pull with needle nose pliers) Step 13: Remove tail light from the motorcycle
Section 2: Removing Stock LED PCB from Tail Light Step 1: Remove (2) 4mm Allen bolts to remove the metal tail light assembly bracket
Step 2: Remove (2) silver Phillips screws Step 3: Remove (2) black Phillips screws holding outer shroud to the LED enclosure
Step 4: Remove the outer black housing from the inner one by pressing in all the (6) tabs gently with a flathead screwdriver (See picture below for tab locations)
CAUTION: The next steps involving the use of heat to soften the sealant material used to prevent condensation and water vapor build up inside the LED enclosure. Be careful when heating the plastic because overheating or overexposure can cause physical deformities in the plastic that are not repairable. Please follow guidelines carefully. Some users have been able to perform the next steps using either a hot air gun or hair dryer.
Step 6: Place the remaining enclosure on a non-metallic container and place on the top rack of the oven. Step 7: Turn the oven heating element off and allow the enclosure to sit in the oven for 15 minutes Warning: The plastic enclosure will be hot when taken out of the oven (duh). Use some kind of protection such as an oven mitt or a towel. Step 8: Test the strength of the sealant by pulling the clear lens from the plastic enclosure.
Step 10: After separating the two pieces make sure that no sealant is left on the outside surfaces of the lens or enclosure plastic. Once the sealant cools it will be very strong and almost impossible to remove without reheating. Step 11: After the enclosure has cooled, use a Phillip’s screwdriver to remove the 2 screws holding the LED PCB to the enclosure.
Step 12: Pull the LED PCB from the enclosure and disconnect the connector on the back of the PCB. Step 13: Remove the grommet and other side of the harnessing from the plastic harness (there are 2 ways to do this): A) If you plan on reinstalling this tail light again in the future, do not cut the connector off! Using needle-nose pliers, press in the tabs on each pin and pull it out of the connector block.
Section 3: Adding Lupus Lights PCB to the Tail Light Step 0: TIP: If you’d like to reuse the OEM grommet, you will have to “gut” it to allow you to pass the connectors through. We used an Exact-O knife to get the desired result. If you don’t want to spend the time gutting the OEM grommet, simply fill the hole that the grommet leaves with sealant material during the resealing process. This makes sure moisture cannot enter the back of the enclosure.
Step 1: Route the wiring harness and connectors through the enclosure opening and make sure none of them will get pinched when attaching the board.
Tip: If reusing the OEM grommet, make sure you reinsert it and twist to secure it! Step 3: Screw in (2) black Phillips screws to hold the circuit board down
Resealing Procedure There are a few ways to reseal the LED lens to the enclosure. They are described as follows: A. Use of an RTV Silicon: Place the two halves of the enclosure on the top rack of the preheated oven set to 260 degrees F for 10 minutes. Please make sure the oven heating element is turned off when the enclosure is placed inside the oven. Remove the pieces from the oven and apply a bead of RTV silicon inside the crevice of the enclosure where the black sealant is located.
the enclosure is placed inside the oven. Remove the pieces from the oven and firmly insert the plastic lens back into the enclosure and let cool. This uses a high performance sealant recommended for head and tail light applications.
Step 6: Screw in (2) silver Phillips screws Step 7: Route wires through tail light bracket and attach (2) 4mm Allen screws
Section 4: Placing Modified Tail Light on Motorcycle Step 1: Plug in the center white running/brake light connector.
Step 2: Reattach the tail light to the rear of the motorcycle using the bolts removed from Sec.
Step 4: Reinstall the seat lock bracket using the (4) 8mm bolts from Sec 1: Step 8 Step 5: Reinsert the two pieces of plastic on both sides of the rear tail (reverse of Sec 1: Step 7)
Step 6: Reinsert the (2) push clips on the bottom side of the rear tail (reverse of Sec 1: Step 6)
Step 7: Reinstall (2) 4mm Allen key bolts from Sec 1: Step 5
Step 8: Reinstall (2) 10mm bolts from Sec 1: Step 4 Step 9: Reconnect the battery to the electrical system.
Step 10: Place the seat back onto the motorcycle
Step 11: Turn on the motorcycle, test the operation of running lights, brake lights, and turn signals. Step 12: Pat yourself on the back… you did it! Enjoy your awesome integrated LED tail light! We would love to get feedback and installation photos! Please send any comments or critiques on how we can make this process easier and send some completed pictures so we can add them to the website.
General Disclaimer Please read all instructions carefully before installing this device on your motorcycle. The content in this manual is for informational purposes only. Lupus Lights makes no representations or warranties with respect to the accuracy or completeness of the content of this document.
