Dual headlight conversion for kawasaki's

[Joker]

STICKY THIS as i wont explain it again.......

this mod will work for ANY kawasaki that has one the low beam as the left light........ it took me a while but i figured it out. here is a write up on how you go about it.
well, Sista said she was annoyed that Kawasaki in their infinite wisdom made the left light only for low beam. so whilst she is away in Europe (with her permission ) i decided since i am off work to fix the problem.

heres what you need for a start....

a 5 pin, 30A relay (if you dont use a switching relay, you WILL melt your plugs, wiring harness and be up shit creek)

2 x H4 socket plugs for headlights

2 H4 bulbs ( the one on the right is the stock h7, notice the difference in size. We are going to have to modify the H4 to fit into the stock headlight)

Tin snips

and finally some wire strippers, electrical tape, and needle nose pliars.


First remove the headlight
(if you need pics for how t do this, do not do this mod. It will be way above your mechanical ability)

next, remove the two circle covers on the back of the housing
pull the sockets off the headlights, remove the rubber circle in the center of the headlight and pull the wiring out throught the hole

now youll notice the h4 is too big to clamp into the housing, so take the tin snips and start cutting down the bracket on the bulb. Your going to have to cut off the outer lip, just keep trimming small amounts and checking to see when it fits. Yo have to remove the cone inside the housing on the low beam side. I reccomend baking it in the oven and removing the front glass to pull it out. Or you can use a heat gun or clow dryer to heat up the glue and pull it out. I just held it with a pair of needle nose pliars and started butting at it with the snips untill i wa able to bend it throught the hole but i did scratch the reflector housing a little. You can only see it when you look real close.


Wire in the H4 plugs with the ground, low beam and high beam wiring plan (once again refer to manula if you dont know this)

replace the covers

now follow the wiring diagram. Do not cut off the harness! you are going to connect the stock plug on the headlight harness into the stock plug on the bike. Cut off the headlight bulb harnesses and splice those into the relay wiring.

Make sure to cut off the rubber cover so you can re use it. You only want to cut the center so it is a single hole and slide it off the old wires.

Run the new wires through it

Tape all your connections

Put the headlights back in and enjoy!!

Headlights on and back together

Low Beam

High Beam

[BigTim]

Nice write-up mate.
Looks shit hot too.

[foolishboy]

Awesome job there Joker, hmm got the same problem with my 'blade, would be nicer if both headlights lit up.

[DRKSIDE]

Excellent job Joker. Youve explained it really well

[Orson]

I'm blessed in that my model of bike is already equipped with dual (H4 also) headlamps. But still wanted to congratulate you on taking the time to do that Joker. I'm sure there are a tonne of peeps who'll be ever grateful and use your advise on this mod. Now you can look forward to wankers flashing you cos they think you've got your H/Bs on. Then they really cop any eyeful when you flash them back with your actual high beam. he he he. Once again, good job

[Stu]

Top write up Joker.

[Joker]

thanks for the replys guys....... i am pretty positive the girly will love it

oh, and took approx 5 hours (cause i have never puled a Kwaka apart b4) and cause i had to remember my relay theory

[Hornet]

PICSOFSISORBAN.


Good write up... I know a guy with a 'Blade that might be able to use that for his.

[Joker]

hahahha thats her mum in the background Hornet

she is in Europe at the moment, which is why i am pulling her bike to pieces hehehehe

[Hornet]

Her mum?
Ooer... don't mention that word around here... Savi might hear and that wouldn't be good for anyone.

Nice to play with other people's toys while they're away, aint it?

[Joker]

SURE IS!!!!!!

she said on her wish list was a fender eliminator, and to somehow get the low beam on both sides..... i have achieved both

with a broken shoulder too hahahaha fucking hurt it a lil today tho. whoops

and yeah, the mod should work on a blade, but the wiring will be a lil different (makes of bike diff) but it shouldnt be too hard to figure out

[Dave M109R]

Top work Joker, might use this in attempt to do the 10.

Might be a bit harder though, different lenses.



Good write up.

[Viper]

i'm gonna do this and the HID conversion at same time. I'm ordering in a HID H4 BI kit and doing this mod. I'll take some piccies along the way.

Might be a couple weeks though

[Twinks]

Yeah very cool write up. Might stop every second person telling me i have a headlight out.

And its always good to have someone work it out for ya.

[Viper]

oooops

[Bunyack]

great right up. one reason I dont like a lot of the newer model bikes is this reason.

[Joker]

Bump, for newer members with the 1 headlight problem

ps:- currently doing a writeup for a Dual headlight HID conversion for an 06 ZX636LE... did it to MrMez's bike

[Pobbler]

I did mine a year ago... best mod ever!!

[B.six]

bah iv been looking into it 4 my R6 because the ports are already there for the globes so it can have an R1's light config. From what i can gather from the yanks tho its a bit of cutting and grinding and i was never good with electrics....i remain 1 headlight out

Is this workable joker?-
http://www.palehorsecycles.com/howto.pdf

[MattyA]

a tad off topic but can you up the wattage of standerd 55/60 gloves to higher ones without fear of melting the reflector/housing?
or hang a couple of dirty big spotlights from the forks.....

^fugly