bd43's 07 Headlight Mod Part 2

[goran21220]

My solution to the problem!It was impossible to take the bolt off cause the nut that is implemented in the plastic part underneath was spinning together with the bolt so i had to cut the plastic around the bolts:
When i put it back i used the soldering gun to melt the plastic and glue the parts together! Best i could do!
BY the way i finished installing bd43's 07 dual headlight harnes and it works great!

[Tailgate]

By coincidence, I installed BD's wire loom yesterday also. I, fortunately, didn't have the spining nut problem but, as I was taking the battery out, both nuts fell out (this is when I learned about the loose 2 nuts underneath). It took a good 10 minutes or so to locate one of them. Once I did that I extracted it with a telescopic magnet. One sure is a lot more familiar with the FZ6 after having done the installation, huh? Now, if somebody points at my headlight I'LL KNOW THAT IT MUST BE OUT! (or do people say "Hey, aren't one of your headlights normally be out?")

[wolfc70]

I completed this mod over the weekend. Everything went smoothly, except for getting at the clamps that go over the throttle bodies. The outside throttle bodies were easy, the middle ones had the clamps turned so I could not get my allen wrench in there. I spent THREE HOURS trying to get at these things so I could remove the air box. I finally got them loose after much cussing. The rest went smoothly, and I had everything back together in less than an hour.

The beam pattern is much better, I can actually see the right (ditch) side of the road. I still think for a modern bike the headlights suck. My old '81 Honda with a 9" single round light lit up more of the road, and has a much better beam pattern, especially on high beam. So far the mucky beam pattern of the FZ6 is my only gripe, and BD43's mod makes it even liveable. I highly recomend this modification, it is simple and BD43's instructions and harness are excellent. Actually if you had to make your own harness, it would not be that hard to do, as it looks more complicated than it really is.

[haasfam]

I was finally able to drive the bike enough to empty the gas tank so I could do this mod. It is awesome!!! It took me a little over an hour to do it (would have been so much faster but the air filter case was a pain to get back on). Anyways, it looks awesome and the cable looks very professional. Thanks Daryl!!!

[Denver_FZ6]

Found a source for pins. I tried going the Dremel route, but it wasn't pretty. Knew I should have taken shop in high school!

I picked up a Metra car stereo harness (AT-WHTY2) for Toyota at the auto parts store. The pins are fairly easy to release from the connector. There are probably 15 of them in the connector so you have a few to practice with. I was able to uncrimp the existing wire and solder my headlight wire in place. It snapped right in to the Yamaha connector.

Great mod Biker_dude!

Hey first post!

FZ6 is first bike too!

[SHinNH]

Just got done doing the mod, and I must say that it wasnt that hard to do, now that I have done it once. Of course being new to motorcycles and such, it was a little wierd taking apart my brand new bike.

Thanks for the great wire kit... it popped in like a breeze...

Thanks
Scott

[Zack]

Finished mod 10 minutes ago. Everything was exactly as post says. Instead saying what went right I'll just say what was a problem:

DISASSEMBLY

* pin was b$tch to make (envy anyone who could buy or get factory pin)
* clamps on air intakes where holding box down snugly

ASSEMBLY

* Had to file and trim pin several times before it went into socket properly
* Bought new Silverstar H4 bulbs. Spent a lot of time trimming a metal forming a skirt socket around a bulb
* Final plug for the RH low beam was smaller than socket needs. When I bent it a bit bigger it didn't go into socket any more. Locking pin in the socket didn't allow terminal to go in either. Had to install terminal the other way and stuff something so it doesn't get pushed backwards when connected onto RH bulb
* Dropped one of the small clamps on the air box outlets below the air box. Wow how many wires, links, inlets, outlets and gizmos are there. Could not find clamp for 10 minutes. Hopefully retrieved it by small telescopic magnet

That was it.

Zack

[CHEMIKER]

I just got BD43's "BD43-DLBH" wire harness in the mail!! It looks very professional, great job BD!

I think I'm as excited to install this as Wavex is to get his new headlight on!

[CHEMIKER]

I got my harness yesterday in the mail and installed it today! WOW, this is professional. The harness is beautifully crafted and the instructions are perfect. It took me 1hr, 15min total with no problems. I didn't experience any airbox hose or battery nut issues.

One thing that took it from difficult to super easy is the gas tank. According to the manual, removal of the tank involves pumping out all of the gas, then removing the tank completely. I would have done this if I hadn't seen BD's pictures from his install. We don't need to remove the tank completely, just get it out of the way so that we can get to the airbox and battery. With BD's method, you remove the two front nuts that hold the tank to the frame but leave the rear bolt in. Using that bolt like a hinge, flip the tank up and then secure it vertically and it's totally out of the way. The advantage is that you don't need a completely empty tank as you can leave the hoses connected.

This fast and cheap upgrade makes a world of difference in visibility at night! And you would not belive how much faster my red one is now

Many thanks BD!!!

[jsteinb95]

Damn Daryl.....how many have you sold?