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post #1 of 8 (permalink) Old 10-15-2007, 10:42 AM Thread Starter
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A cleaner dual headlight mod

Parts I used:
A second front wire harness (you only need two male pins and one female pin from it), 1 ft of 16 ga wire, and a $5 H4 90 Degree Ceramic socket from autolumination.com. I will post pics when I get a chance.

The process:
Remove old harness or grab the harness that you want to sacrifice. (you don't make any mods to the good harness) Take a small screw driver and push on the plastic clip holding the metal pins that are in the plugs for the speedometer. (wire harness side no the speedometer wires)) Pull them out and carefully remove the rubber part from them and remove the wire. You only need to get two of these.

Plug to take them from:
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The pins you need:
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Second step is to remove the entire length of the thick black with yellow strip wire that goes to the right headlight. (ON THE JUNK HARNESS) Again you need to take a screwdriver to remove the female pin out of the plastic plug on the end that hooks up to the bike. A wire will be spliced midway on the black with yellow strip wire, you can carefully cut it off and re-wrap this section with tape.

This is actually the black with green wire, but you get the idea. This is the female plug connection:
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Now that you have these, take the two pins you removed and solder a ft long piece of 16 ga wire to it, with one pin on each end. Now take that piece and route it through the vinyl cover over the harness that goes into the bike. You are going to push the one pin into the plug that the handlebar harness comes into. Push it into the third over spot that would correspond with the green wire that dead ends at this connection.

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On the other end of the wire use the empty spot on the harness connector (not the rounded one). On the other side of this connector you push in the black and yellow wire. Now tape the black and yellow wire to the harness and run it up to the right headlight side. Cut the old headlight bulb plug off and connect the new one so that the top pin goes to your new black and yellow wire and the others are hooked up accordingly. Tape it up nice and now you have a clean headlight mod without any ugly connectors.

Last edited by mbodell; 10-21-2007 at 03:44 PM.
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post #2 of 8 (permalink) Old 10-15-2007, 03:24 PM
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post #3 of 8 (permalink) Old 10-15-2007, 07:30 PM Thread Starter
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Last edited by mbodell; 10-21-2007 at 03:47 PM.
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post #4 of 8 (permalink) Old 10-15-2007, 10:46 PM
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Thanks for the write-up. I added it to the member mod section of the sticky'd FZ6 Aftermarket Mods thread.


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post #5 of 8 (permalink) Old 10-21-2007, 01:17 AM
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Does this make both sides H4? Does it require any cutting. I tried to make as much sense of your post as I could but I am just a little confused. Thanks.
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post #6 of 8 (permalink) Old 10-21-2007, 11:27 AM Thread Starter
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It uses all existing materials. All you need are the pins and some wire along with the bulb harness. This is the same thing as the 2 low & 1 low 1 high headlight mod. This is the same as the one that people cut the lead from the left grip assembly and run a wire to the head light.
The only thing different is that I didn't want to have any unsightly wiring cuts and I wanted it to look stock, so I ran it through the wire harness. I will try and get some better pictures posted shortly. I just have to take apart everything to shoot them.
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post #7 of 8 (permalink) Old 11-04-2007, 02:53 PM
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Why change the headlight plug?

I dont mean to piss in your wheaties but running another wire and putting an offset spade connector terminal isn't that big of a deal, and fits perfectly into the existing one.
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post #8 of 8 (permalink) Old 11-05-2007, 07:28 AM Thread Starter
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Why not?

It looks a hell of a lot nicer this way and it was only $5 for a nice ceramic sealed connector. I am not fortunate enough to live in sunny California or have a garage. I did it the other way for about a year, but the connector prevented the cover from staying down and I didn't like having the spliced wire coming off the controls. It is also a lot more durable this way.
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