Dual Headlights With Write Up

63556 Views 130 Replies 73 Participants Last post by JXHennessy, Jan 10, 2017

nate96

Discussion Starter · Sep 12, 2006 (Edited)

10

I am no longer making these. I sold my bike.

Hopefully the mods dont get mad, as I messed up the last write up and want to start fresh.

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. DO NOT USE 100WATT BULBS FOR THIS)
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.

The relay should look like this

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.

Should look like this

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.

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

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.

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

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

With Both Lights on 100%

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.

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Reactions: 1

81 - 100 of 131 Posts

nate96

Discussion Starter · #81 · Jul 30, 2007

SCREWBEAST- That does the same that I have done. Just way more expensive.

Joe_Rocket

· #82 · Aug 2, 2007

ive thought of this in the past. its annoying when someone says you have a headlight out.. rather that sit there and explain highbeem lowbeen... anymore i just say "oh okay thanks man" and be on my way. ive always thought it would look better with both sides lit up. and cuttin back the power to the highbeam should make it usable without blinding anyone?? yes???
i dont have the tools or place to do it or id attempt it.
add me to that list. 30ish sounds resonable to me

Zeke

· #83 · Aug 15, 2007

Pics

I was wondering if anyone could email the pics to wire this up to me. I am in the military and our internet isnt the greatest so the pics arent showing up.

Recreant

· #84 · Sep 2, 2007

Problem!

Hi everyone. I loved the idea of the dual headlights. So I followed the how-to guide very closely. I finished the project about a week ago and have been driving around all week with no problems. All of a sudden yesterday morning I hopped on the bike, started it up, and I didn't have ANY headlights anymore. I figured it either had to be a burnt headlight fuse or the bulbs burned out. I checked both and neither was bad. So I checked the box. It appears the resistor got so hot it melted part of the case. I believe it ruined the relay. So I took everything off and returned it to stock wiring and I'm still not getting any power through the headlight wires. Anyone have any thoughts or ideas?

rryin

· #85 · Sep 5, 2007

anyone know if i could just add a resistor to the highbeam so it matches my lowbeam all the time? i dont really need the highbeam. hey nate, you work as an electrical engineer or something kuz i know this is the kind of stuff we work with at my job

rryin

· #86 · Sep 6, 2007 (Edited)

i wired the resistor straight from lowbeam power to high beam power and everything worked fine as planned...for a lil while until my lights went out. somewhere along the line i went wrong..gotta go back and check to see what went out:banghead::banghead::banghead:

nate96

Discussion Starter · #87 · Sep 10, 2007 (Edited)

Recreant said:
Hi everyone. I loved the idea of the dual headlights. So I followed the how-to guide very closely. I finished the project about a week ago and have been driving around all week with no problems. All of a sudden yesterday morning I hopped on the bike, started it up, and I didn't have ANY headlights anymore. I figured it either had to be a burnt headlight fuse or the bulbs burned out. I checked both and neither was bad. So I checked the box. It appears the resistor got so hot it melted part of the case. I believe it ruined the relay. So I took everything off and returned it to stock wiring and I'm still not getting any power through the headlight wires. Anyone have any thoughts or ideas?

Recreant- You either didnt use the correct size resistors, wired it wrong, or had some of the wires showing to get a short. In the Cut Off switch, if the wire comes off you wont get any lights. Check there. If not there are some relays by the tank for the lights. Check those if its not the cut off switch. With out me actually seeing what was done or happened, its hard to diagnose the problem.

My bike which I no longer have, has 10 000 miles since being done. The only problem was after the girl that bought my bike dropped it, and the Cut Off switch wire came loose. Fixed that and its still going.

nate96

Discussion Starter · #88 · Sep 10, 2007

rryin said:
i wired the resistor straight from lowbeam power to high beam power and everything worked fine as planned...for a lil while until my lights went out. somewhere along the line i went wrong..gotta go back and check to see what went out:banghead::banghead::banghead:

You just want the high beam side low all the time. Just put the resistors inline on the high beam side. Leave the low beam side alone and just keep the headlight switch on high beams all the time.

rryin

· #89 · Sep 10, 2007

well, i wired it from low beam to highbeam so i could actually utilize the highbeam if i wanted to but i guess it wasnt a good idea because no i have the same problem as recreant. i checked the bulbs and fuse but not the relay under the seat or the switch. what am i looking for in the switch? need to get this fixed asap, i cant ride at night dammmit lol..help.

nate96

Discussion Starter · #90 · Sep 11, 2007

Also check how you wired it. The first time I did it, I wired it wrong and got a short. It just made the ohms go up so less amperage was drawn and the lights would not go on. But there was nothing else wrong to blow the fuse. So if you had your wires to close and hit a bump and caused a short, this could be why aswell.

Code Blue

· #91 · Oct 12, 2007

i was thinking of doing this and just decided on getting hids.. the output is ALOT brighter

jeremyolson84

· #92 · Nov 2, 2007

clearer pictures would help. but good overall.

STi2LGT

· #93 · Nov 5, 2007

I did this tonight, it took me a little over an hour to complete the wiring and soldering. It came out great. I couldn't get a 1 ohm 25watt resistor locally so I took some 1ohm 10watt resistors and wired them in series and parallel to bump my wattage and keep my resistance the same.

49erRider

· #94 · Dec 22, 2007

Hate to kinda bring it back from the dead but is anyone making these anymore?

gee

· #95 · Dec 22, 2007

greAt thread

something i wanted to try for ages....

berzerkus

· #96 · May 6, 2008

FYI i've had this mod for 2 seasons, put on 9k and haven't had any issues other than I had to re-wrap my resistor because of heat. Still recommend it.

dirtyredface

· #97 · May 6, 2008 (Edited)

I was going to try and do this wiring it up should be no problem, but I was wondering where you put the relay and resistors once wired up?

-- Edit: that was a stupid question I just looked at the bike and there is tons of space easy to Velcro down too

JoeZ

· #98 · May 28, 2008

Can someone use RadioShack.com and post part numbers for this? Anxious to do the mod, but not sure which parts through them can be substituted to work...

r_o_b_b_y

· #99 · May 28, 2008

when you do this mod,
do both lights come on on low beam as well as full beam or do you still get the single light when running on low beam?

endleesss

· #100 · Jul 18, 2008

Question, on stock setup low Beam on 100% and High Beam on at 40% power right?
Does this mod make the high beam on 100% all the time? I would like to make both on 100% all the time. Thanks.

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