Dual Headlights on Bike Off High Beam

[Nate]

I have a 2004 CBR 600rr. The high beam is only on when it is switched on. I decided to correct this problem. Here are instructions on how to do it.


Things needed.



1-10amp SPDT Relay.It is also made by NTE. Can use one found at an automotive store. $5.99

1-1ohm 25 watt resistor, or 2-2 ohm resistors wired parallel.$1.49 http://www.nteinc.com/resistor_web/resistors.html

(THIS IS FOR 55-60 WATT BULBS. IF YOU USE 100WATT BULBS YOU WILL NEED TO USE AT LEAST 30WATTS FOR THE RESISTORS. AND WIRE TO THE FUSE BOX FOR ACCESSORY POWER)

I used an enclosure to put the relay I used in it. $4.99

Should be able to find these at an Industrial Electronic Store.

5' of wire

Soldering Iron, and some Solder

1.5 hours of your time



www.active123.com is where I got my stuff. They are located in Canada tho



Add all the wire to the relay. Leaving at least 12" of length for the wires going to the headlights, and about 8" for the ones going to the resistor.

http://i89.photobucket.com/albums/k236/nate96/Tony2B.jpg





The relay should look like this
http://i89.photobucket.com/albums/k236/nate96/Wedding010.jpg


I used mostly all black wire so It looks closer to stock looking.


Then drill out holes in the enclosure. 3 on one side, 2 on the other.

Slide the wires through the holes until the relay is in the enclosure.


http://i89.photobucket.com/albums/k236/nate96/Wedding013.jpg




Should look like this

http://i89.photobucket.com/albums/k236/nate96/Wedding012.jpg





Flip over the enclosure. I put about 5 layers of electrical tape to protect it from the heat of the resistors.



Add the wire to the resistors. Make sure to solder the connections.


http://i89.photobucket.com/albums/k236/nate96/Wedding014.jpg


I then cut the wire, and added some heat shrink. Then taped the resistor to the enclosure.


http://i89.photobucket.com/albums/k236/nate96/Wedding016.jpg




The relay is done.





I placed the enclosure under the instrument cluster using some double sided tape. It is hidden and out of the way.

http://i89.photobucket.com/albums/k236/nate96/Headlights017.jpg


You can follow the first picture on how to wire it to the bike. Solder and heat shrink all of your connections





Stock With One light Low beam

http://i89.photobucket.com/albums/k236/nate96/OneLightLowBeam.jpg





With low Beam on 100% and High Beam on at 40%


http://i89.photobucket.com/albums/k236/nate96/LowBeams.jpg




With Both Lights on 100%


http://i89.photobucket.com/albums/k236/nate96/HighBeams.jpg






This can be done many different ways. This is just how I did it this time.

If I do another I might try to incorporate everything inside an enclosure.

Installation Instructions



Items Needed.






Wire Strippers



Soldering Iron



Solder



Heat Shrink



Heat Gun or Hair Dryer




Place relay under the instrument cluster where it will be mounted.
Move wire 1 to the low beam side, and wires 2,3 & 4 to the high beam side.

Low Beam Side

Cut Low beam side positive side at A(Black with white marks). Make sure to leave enough length so you can solder on new connections.( I added some more wire to mine)
Cut a piece of heat shrink about 1.5” long and place over the wire going to the bike.
Strip back wire 1 and both sides of A.
Solder all 3 ends together
Allow to cool a bit then move the heat shrink over the connection and shrink.


High Beam Side

Power the Light

Cut the High Beam positive side at B(Black with Blue marks). Make sure to leave enough length so you can solder on new connections.( I added some more wire to mine)
Cut a piece of heat shrink about 1.5” long and place over the wire going to the relay.
Strip back wire 2 and E
Solder Both ends together
Allow to cool a bit then move the heat shrink over the connection and shrink


Power the Relay

Cut a piece of heat shrink about 1.5” long and place over the wire going to the bike side at C.
Strip back wire 4 and C
Allow to cool a bit then move the heat shrink over the connection and shrink


Ground the Relay

Cut the High Beam negative side at D(Black ). Make sure to leave enough length so you can solder on new connections.( I added some more wire to mine)
Cut a piece of heat shrink about 1.5” long and place over the wire going to the relay.
Strip back wire 3 and D
Solder Both ends together
Allow to cool a bit then move the heat shrink over the connection and shrink
Remove the piece over the double sided tape and mount permanently



You are Finished







http://i89.photobucket.com/albums/k236/nate96/Tony2B.jpg

http://i89.photobucket.com/albums/k236/nate96/TonyB.jpg

[Supa Dexta]

Informative post..

The reasoning behind the single light, comes from the thinking that if a car is approaching you at night, they may see the two lights and think it's a car that is far away, giving the look of two lights close together. They then pull out in front of you not knowing, its actually a bike thats closer then they thought..

[Nate]

If you are that far away you will have your high beams on any ways. So both lights will be on. And alot of bikes come with only one headlight.

[Luke 96 T/A]

Awesome tips...
I hate people thinking one of my headlights is burnt out!
besides, it they're probably close enough together on my 06 R6, that they'll look like one when they're both on...