Dual headlight mod

[iacob21]

Hello guys. I mounted some LED projector lenses and I also have the dual headlight mod installed. However, every time I turn on the high beam, one projector turns off. On these lenses, the high beam is just a flap that opens and closes. Is there any way to make them both stay on at the same time?

 

[grcamna7]

you are right , so lets say i do the bd43 mod , i could add another h4 bulb so i run a 2x H4 setup with both low on , or both high on ? also connecting both of the H4's low beam to the bd43 wire in the harness?
it should only take a dremmel to cut down the H4 base to fit into the H7 slot .
or you could wire the h7 bulb along with bd43 mod so it goes to high beam

here are some random finds for "inspiration"
pics of someone on here modding h7 and h4 bulbs
for those who did the H4 (dual headlight) mod : Kawasaki ZX Forums: Kawasaki Ninja Forum


how to mod h4 bulb to fit into h7 slot
http://www.sportbikes.net/forums/at...bulb-h4-dual-filament-bulb-headlight-swap.jpg

Have you ever used a plastic template to exchange/fit the right H7 high beam bulb to an H4,like the one in the bottom link ?

 

[Motogiro]

In your case you want the original wire configuration controlling your headlights. Which headlight mod has been done on the bike? There is the original headlamp wire which is a black with a green tracer. This wire should supply both your power supplies for your projectors. Then there is a headlamp wire which is black with a yellow tracer. That wire should be used as your high beam on both your projectors. That wire will control both shutters for your high beam function.
The black wire in your headlamp harness is ground (negative).

 

[grcamna7]

In your case you want the original wire configuration controlling your headlights. Which headlight mod has been done on the bike? There is the original headlamp wire which is a black with a green tracer. This wire should supply both your power supplies for your projectors. Then there is a headlamp wire which is black with a yellow tracer. That wire should be used as your high beam on both your projectors. That wire will control both shutters for your high beam function.
The black wire in your headlamp harness is ground (negative).

Thanks Clif,this is helpful.
I bought the bike stock and haven't yet done any mods;I only have my parking space to work & have only been working on my old car's brakes & staying inside my apt. lately.
When you mention shutters,that's HID ?
Will it be alot of work to install HID's ?

 

[Motogiro]

There are LED and HID projector headlights. They require putting your headlamp assembly in the oven at a specific temperature for a specific amount of time to separate the lens from the headlamp assembly, install the projector assemblies and reassemble the lens to the headlamp assembly.
If the units are a Hi-Lo beam operation, they will have a shutter.

 

[grcamna7]

There are LED and HID projector headlights. They require putting your headlamp assembly in the oven at a specific temperature for a specific amount of time to separate the lens from the headlamp assembly, install the projector assemblies and reassemble the lens to the headlamp assembly.
If the units are a Hi-Lo beam operation, they will have a shutter.

I see
Are the HID LED's light pattern Much better than H4's in the stock positions? Like 'from Night to DAY' better ? I wonder if the HID shutters can be adjusted(I mean for a sharper focus w/ an adj. knob)while riding ?

 

[iacob21]

I see
Are the HID LED's light pattern Much better than H4's in the stock positions? Like 'from Night to DAY' better ? I wonder if the HID shutters can be adjusted(I mean for a sharper focus w/ an adj. knob)while riding ?

They are much better. On low beam, you have constant light on the road ahead of you; with high beam on, you can see maybe 100 meters ahead.

You can fully adjust them using the original screws on the headlight.

 

[iacob21]

In your case you want the original wire configuration controlling your headlights. Which headlight mod has been done on the bike? There is the original headlamp wire which is a black with a green tracer. This wire should supply both your power supplies for your projectors. Then there is a headlamp wire which is black with a yellow tracer. That wire should be used as your high beam on both your projectors. That wire will control both shutters for your high beam function.
The black wire in your headlamp harness is ground (negative).

The connection for the high beam is like this: I put both cables from the HID projector into one connector plug, then connect that plug to the original high beam harness.

For the low beam, I have it like this: for the right side, I just used a connector for the original harness. For the left side, I have the dual light mod (I didn't make this mod; I bought the bike like this) with a positive wire that I don't know where it's going and a negative that goes directly to the battery.

If I switch to high beam, the one with the mod turns off. But if I press the pass/flash button and keep it pressed, both of them work. I really don't understand where the problem is.

 

[Motogiro]

Instead of using the headlight mod wire for power to your headlights you want to use the original black with green tracer wire that should still exist in the harness that originally supplied the OEM headlights. Use the black with yellow tracer for your high beam shutter control.

The wire you're using turns off when the high beam switch is turned on/off for proper H4 operation. The H4 has 2 filaments and one filament (low beam) should turn off during high beam function. The original FZ6 head light did not use the low beam filament. It only used the high beam filament in that lamp. The FZ6 could use the low beam filament but needed to turn off the low beam filament if you used the high beam filament in that lamp to prevent premature failure from over heating.
It might be a little tricky to follow the design and reasoning of the original design and then modifications to have both lamps working.

The important part is your original harness has the 3 wires you need for your projector supply. The original black with green tracer wire will be your projector power feeds and will not turn off when you turn on your high beam. The original black with yellow tracer wire will operate your Projector shutters.Black wire is negative/ground.

Also you have to start the bike when testing the headlamp feeds because there is a headlamp relay that activates after the engine starts. You can start the bike and the hit the kill switch so that the headlamp relay stays active until the ignition key is turned off

Have fun and be safe.

 

[iacob21]

Instead of using the headlight mod wire for power to your headlights you want to use the original black with green tracer wire that should still exist in the harness that originally supplied the OEM headlights. Use the black with yellow tracer for your high beam shutter control.

The wire you're using turns off when the high beam switch is turned on for proper H4 operation. The H4 has 2 filaments and one filament (low beam) should turn off during high beam function. The original FZ6 head light did not use the low beam filament. It only used the high beam filament in that lamp. The FZ6 could use the low beam filament but needed to turn off the low beam filament if you used the high beam filament in that lamp to prevent premature failure from over heating.
It might be a little tricky to follow the design and reasoning of the original design and then modifications to have both lamps working.

The important part is your original harness has the 3 wires you need for your projector supply. The original black with green tracer wire will be your projector power feed and will not turn off when you turn on your high beam. The original black with yellow tracer wire will operate your Projector shutters.Black wire is negative/ground.

Also you have to start the bike when testing the headlamp feeds because there is a headlamp relay that activates after the engine starts. You can start the bike and the hit the kill switch so that the headlamp relay stays active until the ignition key is turned off

Have fun and be safe.

Thanks for this really good explanation, I will try this tomorrow.

 

[trepetti]

This is the wire that needs to be added. For whatever reason they leave it off. This wire goes hot (on) when the high beams are OFF. Yamaha built it all in to the wiring, then left it disconnected....

 

[iacob21]

I just finished the wiring, and finally everything works. What do you guys think about the battery voltage?

 

[grcamna7]

This is the wire that needs to be added. For whatever reason they leave it off. This wire goes hot (on) when the high beams are OFF. Yamaha built it all in to the wiring, then left it disconnected....

Black w/ yellow stripe connecting to the solid yellow ?

 

[TownsendsFJR1300]

Tom, that WOULD BE the BD43 mod correct?

.

 

[Motogiro]

View attachment 93913
This is the wire that needs to be added. For whatever reason they leave it off. This wire goes hot (on) when the high beams are OFF. Yamaha built it all in to the wiring, then left it disconnected....

This is correct. The H4 lamp has design such as it was probably more economical to create the high beam function with it as apposed to the H7. Since they weren't using the low beam filament they saved the wire cost. Unfortunately we are not allowed to use Yamaha materials anymore. I wish we could because life would be much better. We used to but we now have to follow legal protocol.

 

[Motogiro]

Tom, that WOULD BE the BD43 mod correct?

.

Yes, Adding a wire between those 2 points would be what we commonly call the BD43 mod. There were other bikes (not FZ6) that had dual head lights similar to the FZ6 headlight configuration but had different wiring than the FZ6. This would require a different approach.
I used to make a relay assembly that was universal to fit those variables in wiring. I quit making them because too many folks had issues with the reflector design in the FZ6 headlamp assembly. Using the low beam might require re-aiming that eye. I was spending too much time helping people understand aiming issues. This would also apply to the BD43. There was the issue of re-aiming in any case. I didn't profit from my relay assembly and it was more of a fun project until it cost to much time.

 

[Motogiro]

Black w/ yellow stripe connecting to the solid yellow ?

What solid yellow wire?

 

[grcamna7]

What solid yellow wire?

I'm referring to the diagram in post #51 where the red arrow looks like it touches the yellow wire,although now I see it may point to the end of the plug on the right side? w/ a black wire? according to trepetti's color diagram.

 

[Motogiro]

I'm referring to the diagram in post #51 where the red arrow looks like it touches the yellow wire,although now I see it may point to the end of the plug on the right side? w/ a black wire? according to trepetti's color diagram.

Yes. See that little letter B where the wire color changes? That is at the plug for the headlight harness. High beam voltage.

 

[grcamna7]

Yes. See that little letter B where the wire color changes? That is at the plug for the headlight harness. High beam voltage.

I see a 62 in a circle next to where the black changes to black/yellow tracer.