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In another post, I mentioned the left handlebar switch where the high/low beam switch resides. I also talked about the connector from the left handlebar switch mating to the wiring harness on the frame side that wanders off to the lights, horn, etc.
www.600riders.com
The important note here is the low beam wire from the switch is factory wired to the connector with the mating frame connector not having a pin to go no where. This mod exploits the use of that empty pin and utilizes the factory pre-wired low beam wire from the switch. Unfortunately, part 1 of this mod is not that easy to do and I apologize for its complexity, but once you see where this mod goes, it is the most non-evasive low beam mod that does not destroy the factory wire harness. Let’s begin.
Unless you can find a source for the pin that inserts into the frame connector, then one needs to be fabricated.
Here are the dimensions for making a pin out or 0.025” brass plating that will fit into the male connector that mates to the left side switch assembly.
www.600riders.com
Using a metal nibbler, metal file, mini saw, Dremel grinding tool, or what have you, to fabricate this pin. This is the hardest part of the mod short of finding the pin from another source such as AMP.
www.600riders.com
Tinning exposed surfaces is important as it prevents corrosion. Clean both sides of the brass pin with steel wool or a pencil eraser as best as possible. Coat the surface with solder flux and then tin the surface with solder. This process will not work if the surface is not CLEAN.
www.600riders.com
Once the pin has been tinned, bend the tabs over as shown in this photo making the bends as close to the middle as possible. These tabs are for locking the pin into the connector housing when it is inserted. The end tabs are not bent all the way because this is where the wire will rest.
www.600riders.com
Left Handlebar Switch
The left handle bar switch is of interest because a few people are doing their headlight mod around it, either by tapping into the harness directly after the switch or somewhere down the line closer to the headlights. The manual is pretty clear about what lies further down from the switch...
The important note here is the low beam wire from the switch is factory wired to the connector with the mating frame connector not having a pin to go no where. This mod exploits the use of that empty pin and utilizes the factory pre-wired low beam wire from the switch. Unfortunately, part 1 of this mod is not that easy to do and I apologize for its complexity, but once you see where this mod goes, it is the most non-evasive low beam mod that does not destroy the factory wire harness. Let’s begin.
Unless you can find a source for the pin that inserts into the frame connector, then one needs to be fabricated.
Here are the dimensions for making a pin out or 0.025” brass plating that will fit into the male connector that mates to the left side switch assembly.
dp_fz6_54.JPG
Using a metal nibbler, metal file, mini saw, Dremel grinding tool, or what have you, to fabricate this pin. This is the hardest part of the mod short of finding the pin from another source such as AMP.
dp_071103_04.JPG
Tinning exposed surfaces is important as it prevents corrosion. Clean both sides of the brass pin with steel wool or a pencil eraser as best as possible. Coat the surface with solder flux and then tin the surface with solder. This process will not work if the surface is not CLEAN.
dp_071103_05.JPG
Once the pin has been tinned, bend the tabs over as shown in this photo making the bends as close to the middle as possible. These tabs are for locking the pin into the connector housing when it is inserted. The end tabs are not bent all the way because this is where the wire will rest.
dp_071103_06.JPG
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