bd43's 07 Headlight Mod Part 2

[bd43]

OneTrack;

I'm glad the mod worked out for you! That looks great. It would be interesting to see how far back in years this wire harness is good for or how the UK boys will make out, hopefully next week.

Service manual for 2004 through to 2006 seem to show the same switch connector configuration so I would think this would be good for all years. We'll have to see.

I think it took about 15 minutes for me to remove my airbox and battery to get to the connector. Did you have any problems in this area?

[midnightfz6]

I've just received and installed biker_dude43's dual headlight harness. Thanks Daryl. Great piece of work. Very tidily made, looks like it's factory wiring when installed. Took me an hour to install once I had the right tools. Had to go out and buy a long 4mm hex-key for the clamp around the throttle body. It needs to be at least 130mm long. It was my first time taking off the airbox. Not difficult at all, don't let it stop you doing the mod. If you're experienced with removing the airbox/ battery/ cover then you'll have it done even quicker.
No cables have to be cut, spliced, or soldered.
My bike is the UK 2007 S2 and the harness connectors fit perfectly.

[OneTrack]

Originally Posted by biker_dude43

OneTrack;
I think it took about 15 minutes for me to remove my airbox and battery to get to the connector. Did you have any problems in this area?

The only "mod" I had done on my bike prior to installing the harness was the FE kit, so removing the inner fairings, tank, airbox and battery/battery box was a first timer for me. Now that I've done it once, it'll be much easier and quicker next time if I want to get at the same area again (and I'm sure I will.... )
Once the "order" of disassembly/assembly is remembered, it is a piece of cake.

[Nelly]

Hi all got my wiring harness from Daryl this morning.
The quality is excellent. It only took about 6 days to get here. Very rapid indeed, we are awaiting our third baby this week so I might have to pop out in between contractions to install lol. I would love to get it done over the winter though, as the lights IMO are one of the weakest features of the bike. As a complete novice to all things electrical I will let you know how I got on.

[opds9091]

so when i get it and do the install, on my low beams both light will be lite without people flashing me cause i have the high beam light in there eyes. Basicly on the low beam there will only be low beam light on?

[bd43]

There were some questions about confirming whether or not you are looking at the correct wires or pin location when doing this modification. For some, it can be an overwhelming ordeal to gain access to the connector because of the removal of the air box and battery box. It would be nice to get it right the first time, in case there was some doubt. After looking a the 2004, 2006, and 2007 wiring diagrams in the respective service manuals, I believe that the following information should be correct but sometimes literature or people can be wrong. Verify if you feel the need to re-assure yourself as, hey, it’s your bike, right? The 2005 service manual did not have a wiring diagram in it but going from the 2004 to 2006 showed no change so I would assume 2005 would be the same.

The simplest way to confirm that you are tapping into the right wire is turn it on, right? Since the air box and battery has been removed, that kind of eliminates this test. The only thing left that you can do is perform a resistive check with an ohm meter or DVM.

Let’s take a crash course on wiring schematics. Before we do the test, it helps to see schematically what the wire harness actually does. In the Schematic_1 taken from the 2004 service manual, I have laid a red line from the bottom of the dashed box outline (item 53) to the lower part of the wiring schematic and ending at the hi-lo bulb (item 62). That red line, or the wire harness provides a path for the (+) side of the battery to the lo-beam filament when the hi-lo beam switch (item 55) is switched to lo-beam.

Schematic_2 is a close-up shot of item 53, the female connector from the left handlebar switch assembly. Everything contained within the dashed box outline is the switch assembly. Item 55 is the hi-lo beam switch. I have drawn it electrical as something everyone should be familiar with at the bottom of this schematic. As that little drawing of mine indicates, when item 55, the hi-lo beam switch is on hi-beam, the light blue common line makes contact with the yellow line. When the switch is flipped to lo-beam, the light blue common line makes contact with the green line. Inside the dashed box, I’ve outlined in a solid red box the female connector toward the upper left. This indicates where on the connector you should expect to find these three wires that I mentioned, as they are also appropriately labeled along the black lines or wires that are leaving the dashed box line. Given now the colors of wires that you are looking for and the possible location that they can be found on the female connector, using an ohm meter you can test the continuity of the light blue to yellow for hi-beam and the light blue to green for lo-beam. In other words, you are looking for zero ohms or a short between the light blue and yellow when the switch is in hi-beam while an open or infinite ohms or resistance between light blue and green. When the switch is flipped to lo-beam, the opposite is true.

I hope this is useful to someone. I’m not a Yamaha service tech person nor work in that end of the service sector, just a messenger, so don’t shoot me if I’m wrong.

[blueMONday]

I received my wiring harness from Daryl yesterday and did the install tonight.
The workmanship of the dual headlight wire harness is top quality, bordering perfection (must be the obsessive/compulsive behavior of engineers, LOL). Approximately it took 6 business days for the harness to arrive (snail mail, too bad email can't be applied to this). FYI I "used to" do most of my car maintainance: simple tune ups, oil change, and electrical work to name a few and I do mean a few. So I'm not exactly unfamiliar with engine work but I do limit it since some "Joe" mechanic out there needs to feed his family
The actual install took me 1.5 hours (motorcycle engine, sheesh) from start to finish. Much of the work was spent locating the wire harness and triple checking
that I match the female connector to the empty slot where the "male" pin connector will be inserted. Now after wasting enough time doing this I finally commited myself into pushing the pin into the correct empty slot. NOTE: BE VERY VERY CAREFULL NOT TO PUSH THE PIN "TOO FAR" IN !! I had the misfortune of doing this, luckily a simple micro screwdriver (used for wristwatches) can easily remedy this. Then the rest is just simply following
the simple instructions that came with the wire harness. I did find it usefull to
refer back this forum for this thread via my laptop. After reversing all that i did to get into the engine all I needed to do was fire up the Enterprise and Voila!!! Dual Headlights....... very very nice indeed. Now my buddy can't joke about one of my lights is busted, hehehe. Overall I give this mod a 5 out 5, "light" and sweet just like my Dunkin Donuts coffee. Thanks a bunch Daryll.

[Nelly]

So Daryl,
are you saying that essentially their is the same lighting loom in 2006 & 2007 modles.

Cheers.

ps I loved youe explanation of wiring Schematics. Didin't understand a word of it lol.

[bd43]

Originally Posted by perryn

So Daryl,
are you saying that essentially their is the same lighting loom in 2006 & 2007 modles.

To date, it seems that the 2006 and 2007 bikes have the same connector as installations have been performed on both years here in North America and in the UK. According to the 2004 Service Manual, it shows the same connector configuration as the 2006 and 2007 which would lead one to believe that it should be the same from 2004 upto 2007, and dare I say 2008?

Side note: It's kind of weird why Yamaha ran the wire from the low beam side of the switch to the connector. Either they were originally thinking of this wire connection or the left handlebar switch is used on another model of bike that does use it? Why?

[bd43]

Originally Posted by perryn

I loved youe explanation of wiring Schematics. Didin't understand a word of it lol.

LOL, I guess all that schooling of mine paid off. My mother would be proud!