bd43's 07 Headlight Mod Part 2

[Scorphonic]

just to get rid of some of your worries about why Yamaha didn't wire up the light. I was in with my Yamaha dealer yesterday and today and I explained what was going on with the bike. I told them that it was possible to hook the right hand "high beam" light up so that it lit up as a low beam also...it having two filaments and all!!!

At first they did not believe that it was a double filament because even they were confused why Yamaha didn't hook up the other light. They said that it must be due to local or national regulations of lighting of motorcycles...and hence why Yamaha refused to answer any questions related to this set up on the bike. (They said Yamaha frequently refuse to answer questions!!!)

[vinpub]

Finished Biker-Dude's headlight mod yesterday (or rather early this morning). I have a 2005FZ6 and his instructions, including color codes matched exactly. His instructions are very accurate and detailed. (Please note: If you are tracing the electrical diagram in the manual, it msistates 61 as HIgh beam and 62 as Low beam on page 8-28. It shoudl be other way around. This will confuse your wire color tracing).
His instruction on the other hand are detailed and accurate. I highly encourage anyone intersted in the headlight mod to look into this. The wiring looks vey professional and there is no wire stripping.
It is a litle bit more involved and time consuming, since you have to remove (or hold up) the tank, air filter box and the battery.
I took two attempts - first time I didnt get time to get into the air filter box. Second time, starting from the beginning it took me ~4 hrs. But I was slow and I forgot to connect the hoses back the first time. So I had to disassemble and reassemble everything.
The mod works and looks great, worth the time and efforts,

[Scorphonic]

I was out looking at the bike today, Can someone tell me how to remove the airbox from the bike? I had removed the nuts from the battery area and the two nuts for the airbox nearest the battery housing. Are the only things remaining holding the airbox in place those thick pipes (three to the back of the airbox near the riders seat and one along the right hand side of the airbox) ?

Do I have to remove anything else? I understand that after I remove the airbox unit all I have to do after that is move the battery housing backwards to reveal the wire connector.

[vinpub]

I was stuck at the same spot as you/
Take a look at the service manual for air box removal. Besides all the screws you will have to disconnect the 4 hoses (3 on the back and 1 on the right which is a little hard to get to). You will also have to disconnect a green regulator on the back (right next to the hoses). Then I just lifted the box out - it will pop. In my case I couln't get to the hose on the right so I lifted the box out carefully without jerking it too much and then disconnected the hose on the side. When mounting it back, I connected that hose first and then wriggled the box in place. Just make sure it sits in nice and tight on the air pipes below.
There are screws on the bottom which are hard to get to taht tighten a ring around the 4 pipes underneath. I didnt see them until I poped the box out. The service manual didnt say anything about it, May be if you can get to them and loosen them a turn or so, it will be easier to pop the air box out - that's just a guess. Doesn't seem that it is required as service manual doesnt say anything about them.

[Scorphonic]

O your a legend vinpub!!

A perfect answer for a simpleton like myself!!! I know exactly how to take it off now...thanks a million!

[Scorphonic]

I got the wire harness from biker dude the other day, and got to it straight away today (when I got home from Uni!). The mod took me 2 hours...all because it was dark and I was doing everything by feel and by a bad torch light!

I got everything back together again but the two screws for the airbox (beside the battery box) just wont bite so I'll have to take a look at that tomorrow...

I can safely say that this mod is amazing...and your wire harness is just made to perfection!!! You did say that a special tool is required to remove the pin if you put it in the wrong hole but I found a glasses screwdriver just perfect for when I inserted in the pin too far into the correct hole!!

The bike looks a million dollars, pounds...euro...whatever your currency!

Thanks again!

[opds9091]

this is another mod for this weekend, just great. I ahve a question. With the mod done, the low beam lite lights both lights right. BUT, if so, is the low beam lights on low beam or do people still brite you cause the high beam light is blinding them, OR, does this mod get ride of the blinding high beam light, OR, do you have to buy a low beam bulb and replace the high beam with a low beam bulb. I HOPE THAT MADE SENCE.

[Scorphonic]

take a step back here for a second opds!

The two lights on the bike are capable of lighting up when you turn on the engine as LOW beams. The right is also capable of high beam when you flick the headlilght switch. This mod only connects the vacant plug on the right hand light to the plug under your battery where there is actually an empty male slot and the female slot is there waiting to be filled!! Oooo Matron!!

So yamaha have wired up the bike to the female plug stage and this mod only connects the female part to the light bulb itself via biker dude's handmade wire loom.

everything we need to have the two lights shine on LOW beam are there...the only thing missing is the wire connection from the electronics to the empty slot on the right hand bulb. This connection is Biker dudes wire loom.

Remember, like all other motorcycle lights....When low beam is on in the right bulb the high beam is OFF, when you turn on the HIGH beam the low beam is OFF in the right bulb. only one filament in that bulb is on at any one time. So with this mod and when you have LOW beam selected on the left handlebar you will NOT blind any drivers as the beam does not go higher than their bonnet (so long as the light is aligned correctly of course!!)

There really is nothing complicated about this mod, its simply finishing off the work that Yamaha didn't bother their a s s to do...its non invasive.

[opds9091]

much and many thanks for that. I was not sure about it as i was looking at some of the finished pic's and i still or thought i saw two different beams of lights, but thank you for answering it for me. i can breathe easier now

[bd43]

Originally Posted by opds9091

this is another mod for this weekend, just great. I ahve a question. With the mod done, the low beam lite lights both lights right. BUT, if so, is the low beam lights on low beam or do people still brite you cause the high beam light is blinding them, OR, does this mod get ride of the blinding high beam light, OR, do you have to buy a low beam bulb and replace the high beam with a low beam bulb. I HOPE THAT MADE SENCE.

opds9091, like Scorphonic explained, the light bulb on the right hand side sitting on the bike looking forward is equipped with a low beam filament and a high beam filament (H4 bulb). Yamaha's stock harness only provides power to the high beam filament only when the left handlebar switch is switched to high beam. When the switch is not in high beam, that filament is off, agreed? So, if it is off (switch not in high beam), why not power the lowbeam filament of the H4 bulb? That's what my harness does. Maybe the confusion is not understanding the construction of an H4 bulb. In the attached photo, notice the low beam and high beam filament. The high beam filament has a lower resistance that causes it to draw more power thus provide higher intensity while the low beam filament has a higher resistance drawing less power thus lower intensity. Think of the light bulbs in your house. A 40 watter is not as bright as a 60 watter. The H4 bulb has both these bulbs in one except it is typically 55w and 60w. Also notice in the photo that there is a reflective shield to the right of the low beam filament. That shield actually blocks light from illuminating 360° around when the low beam filament is powered which also means that light reflected off the headlight assembly on the bike is not fully utilized, also diminishing the overall effective brightness as viewed by oncoming traffic. The end result is when the right side low beam is lit with the left side one, the overall viewing intensity will not seem like high beam intensity light to oncoming traffic. Only when switching to high beam will this be true. I hope that clarifies things up a little.

Good luck with the install!