How To: Flush Brake Light with Fender

So a few people have asked me how to make the tail light sit flush with the fender. Here's how I did it. This will NOT cover wiring installation, rather just the hardware mounting.

*I actually stared out with the ZX6R light. It ended up failing so I purchased the Custom LED Blaster x. Butterfingers that I am, I dropped it right out of the box and broke the light housing. So I took the Custom LED guts out and thank God they still worked. I popped them into the Smoked ZX6R housing. So while it looks like I have a ZX6R, it's actually the new Custom LED Blaster X.

Materials Needed:

• 
  [li]Custom LED http://www.customled.com/products/integrators/Stryker_tail_light/stryker_tail_light.htm[/li]
  [li] OR the Kawi ZX6R (cheap but not as reliable) http://www.ebay.com/itm/Integrated-Taillight-Brake-Tail-light-Kawasaki-ZX6R-ZX-6R-2007-2008-/390432520185?pt=Motorcycles_Parts_Accessories&hash=item5ae79777f9&vxp=mtr [/li]
  [li]License plate reloation Bracket http://www.road6customs.com/online-shop.html#ecwid:category=337153&mode=product&product=1136460[/li]
  [li]2 Bolts 1 8x16[/li]
  [li]2 washers[/li]
  [li]6 nuts[/li]
  [li]zip ties[/li]

Tools Needed:

• 
  [li]10mm socket wrench[/li]
  [li]6mm Allen wrench[/li]
  [li]Hacksaw/dremel[/li]
  [li]Phillips Screw driver[/li]
  [li]Adj. wrench/crescent wrench[/li]
  [li]Drill and 1/4" bit[/li]

1. Fender Removal (*optional; makes it easy to install any wiring necessary)
Remove the seat and with the 10mm socket, unbolt the brackets on the fenders on top (pictured below are black screws). Using the 6mm allen, remove the fender stays on the side. The black plastic clips on the front of the fender stays pull straight out. Using anything pointy, press in the center of the clips under the seat just rear of the battery.


2. Tail Light Assy removal

Using the 10mm socket, remove the two nuts and two bolts shown. Keep them and the four washers in a safe place. The unit will come down and slide to the left. Unclip the wiring harnesses and cut the zip ties holding the wires in place.


3. Cutting the Goods

Here you will need to seriously reduce the amount of plastic and metal.

3.a Trim the plastic roughly to the same shape as shown below. The square cut out on top was a relief made to accommodate for the metal bracket being placed vertically higher. My hacksaw broke and it was easier to trim the plastic than it was to trim the metal. When reinstalled, it will sit tucked inside the fender.


3.b Trim the metal to roughly the same shape as below. Drill 1/4" holes 7mm below the original mounting holes on the top of the metal piece. This will raise the whole assembly to be closer with the fender when installed.


4. Mounting
Using the diagram below, position the nuts and bolts through your new holes in the metal mounting plate. The length of the bolts will allow the light to sit further inside the fender horizontally.


5. Plug in the wiring harnesses and ziptie the wires in a safe manner. Reinstall everything.


6. The multiple nut system allows you to adjust precisely how much the brake housing sticks out of the fender while installed on the fender (as opposed to spacers which are a fixed length). This is what it looks like from the bottom. Tighten fasteners for desired results.


Finished!



Original ZX6R light and housing in the above two pictures.