Thursday, 1 May 2008

Dual Headlight mod - HOW TO

This mod is really easy, even for people with very limited experience. To begin, you will need:

1) some additional wire to connect bulb to bike's current wiring

2)a terminal connector to connect the wire's end to the H4 bulb. If you are not which size the connector has, just ask one or two connector for a H4 bulb from any cars' electrician. He'll know (radioShack calls them Female quick disconnect .250"). You will only need one of them. If you can't find a female, a male will still do but it is not preferred. A female will allow the switch in the fairing to close after mod, the male will not.

3)Many cable zip ties (I opted for black ones)

4)Thin wire loom

5)black electrician's tape


So,

step 1: Solder the connector to the one end of the wire. If you don't solder the wire may be easier to break loose.

step 2: Tape the wire with black electricians tape all the way. Just leave enough room at the ends to help recognising the color of the wire.

step 3: Splice the wire loom on the left hand handlebar(clutch side). Find the green wire with the orange dots. Cut its insulation. Cutting the wire is not needed.

step4: Run the taped wire from the buld to the handlebar, following the excisting wires. This will make the mod harder to spot. Use cable ties to secure the wire in place.

step5: Connect the new wire with the green wire. After connecting, place plenty of electricians tape to make sure the connection stays properly insulated in the future.

step 6: Place new, black wire loom above spliced. Zip tie to secure.


Mod is done. Make sure you:

1)Check it works before tidying up

2)If you own a faired FZ6 be carefull when placing back the inner fairings. Do not scratch the outers, many people (including me) have done this....

3)Euro spec bikes will need to connect the wire to the left side headlight. The US bike will connect to the right side headlight. The rest of the proceedure is the same for both bikes.

4) These pictures (owned by WTVa) may be usefull to you before you start. http://community.webshots.com/album/169586128FWwiZU