Rotary Extreme - Rotary Extreme Sleek Headlight Kit Installation

Rotary Extreme Sleek Headlight Kit Installation (Updated 6-20-06):

Thank you for purchasing the Rotary Extreme headlight kit for the 93+ RX-7. With proper installation and proper headlight adjustment, you should find the light kit to be the best and most affordable on the market today. If you have any installation questions, please email rotaryextreme@aol.com for support.

Warning:

Please wear eye protection goggle and mechanic gloves when installing the light kit. The brackets are sharp. Please handle with care.

Caution:

Please read this installation page completely before you attempt the installation.

Tools you will need:

Sockets (metric size with at least 10mm, 11mm, and 12mm sockets), wrench (metric size, 10mm, 11mm, 12mm), screw drivers, wire crimping tool, drill, drill bits (1/4"), cutting wheel, touch up paint, and clamps.

Hardware you will need:

14 gauge wires, 3M acrylic double sided molding tape, and silicone sealant, permanent marker or white out. Relay with 30A fuse if you wish to turn on both high beam and low beam while the light switch is at the high beam position.

Cutting the frame:

1. Take out the stock headlight system. Please refer to the shop manual for details. The photos below will help you to locate the bolts and panels you have to remove.

2. The installation requires cutting the frame. Use the top part of the light mounting bracket as a template. Trace the edges of the mounting bracket using either permanent marker, whiteout or masking tape onto the frame and cut the frame accordingly. Use touch up paint on all the bare metal to prevent rust.

If you have the HID Kit, you need to cut the frame more and you also need to cut the upper bracket to clear the HID ballast connector.

You need to lower the wire loom to clear the headlight brackets. The wire loom is secured onto the frame. Push the tabs out to unbolt the wire loom.

Headlight assembly:

3. Assemble the light mounting bracket assembly as shown below. Note that the mounting holes on the rectangular bracket is larger. You can adjust the overall height of the rectangular brackets up and down in case the projector hits the headlight cover.

Test fit the brackets on the car and make sure the brackets are not interfering with any wires or the frame. The top part of the mounting assembly mounts onto the frame using the stock headlight mounting holes (circled in the photo below).

If you have the HID low beam, you need to drill one more hole on the upper bracket through the frame and use a bolt and nut to secure the upper bracket onto the frame.

4. Unbolt the headlight mounting brackets from the frame. Assemble the lights onto the mounting brackets. The kit comes with 12 springs and 12 adjustment bolts.

5. First, assemble the high beam (brown light housing) onto the mounting bracket using the 2.5" bolts and spring.. Each light takes 3 springs and 3 bolts. The spring will have to be sandwiched between two washers. Use another washer on the back of the bracket where the nut screws into the bolts.

Mount the adjustment bolts the same way on all 3 corners. Screw the bolts in until the light bulb connector is on the opposite side of the headlight housings. Try the connector on to make sure the connector will clear the bracket.

6. Follow the same procedure for the projector low beam. Screw in just enough for the bolt to be flush with the nylon locknut.

7. Mount the headlight assembly onto the chassis.

Note: The photos above show the bracket for the low beam HID. For regular Halogen light kit, use the stock mounting points.

Headlight Wiring:

The stock headlight connector has 3 wires consisted of two red wires and one black wire. The bottom red wire is for low beam. The left hand side red wire is for high beam and the right hand side black wire is for ground. You can use our H4 connector adapter to connect the lights to the stock wiring. Please make sure the wires are long enough to reach the headlight assembly. Connect both ground part of the Hella H9 connectors to the stock headlight ground wire (black) and +12V wires on the Hella H9 connectors to the separate red wires on the stock connector wire. Make sure you mark which H9 connector is for high beam and which one is for low beam. To make the connectors, you need to use a special crimping tool for the pins. You can get the tool from Radio Shack. When you finish making the connectors, they will look the below:

If you wish to turn on both high beam and low beam while the light switch is at the high beam position, you will have to run an additional relay with a 30A fuse. You should be able to find a relay kit at your local auto parts store. The relay kit for the fuel pump also works in this application. On the relay, there are 4 terminals:

Battery +
Ground
+12V signal source
+12V output

You will need to hook up the relay to only one side of the headlight wiring unless you are running a high voltage light bulb. If you don't want to take the risk of overloading the wiring, you can install relays on both sides of the headlight wiring.

Connect the Battery+ and Ground terminals to the battery. It's easier if you do this on the driver side of the headlight kit since the battery is near by.
Splice the +12V signal source terminal to the high beam red wire on the stock headlight connector.
Use a 3 way butt connector to connect the +12V output terminal to the low beam H9 +12V wire.
Make sure you put the 30A fuse to somewhere you can easily access.
Connect the H9 connectors to the respective Hella 90mm lights and switch on the headlights to see if they work accordingly.

Light adjustment and housing mounting:

Warning: Do not mount the housings permanently on the car until light adjustment is done.

1. Aim both the low beam and high beam by using the adjustment screws. The bottom two screws are for horizontal adjustment and the top one is for vertical adjustment.

2. Try to put on the Lexan covers to see if the lights are back enough for the Lexan covers to clear. If the lights are sitting too much forward, please adjust accordingly and repeat 2-6. Please position the low beam projector as forward as possible. This will provide better lighting.

3. When pre-fitting of everything is ok, you can start to mark the holes on the chassis where the side bracket on the housings should be on. You should secure the side mounting bracket on the chassis first using the provided M6 Allen bolts and locknuts and then secure the light housings onto the bracket. This way, you do not have to remove the bumper. Use the stock 6mm bolts to secure the top light mounting bracket. The brackets will look like the photos below once you have them mounted.

9. Do the final adjustment. Do not put on the Lexan Covers permanently yet.

10. Clean the housings with rubbing alcohol. Put the 3M double sided molding tape onto the edges of the headlight housings. The 3M acrylic tape looks like below:

Close the hood and then put on the cover while the hood is closed so you can make sure the covers will not interfere with the hood. Press firmly around the edge of the Lexan covers to make sure the covers are secured onto the housings. Please put the Lexan covers as forward as possible. If the trim at the front edge of the cover is blocking the light beam, you are not putting them on correctly. After the covers are secured onto the housings, unbolt the housings from the car, clamp down the edges of the covers with clamps and heat up the covers with a heat gun. That will set the covers into the contours of the headlight housings. After the covers cool down and set into shape, seal the edges with silicone sealant or silicone gasket maker which you can buy at any local auto parts store. To make it clean, tape up the housings with masking tape so the silicone will not get all over the place.

11. Bolt the headlight housings back on the car. Turn on your lights to make sure everything is in working order. Check the light beams to see if there is any final adjustment needs to be done. Adjustment of the light beams is the key to the performance of this light kit and it has to be very accurate. Please be patient.

12. Congratulations! You have finished installing the Rotary Extreme Sleeklight Kit.