RELATED MODS: XEON Headlight Bulbs

Ok, I'm going to cheat here a little bit and outline what is the best method of performing a dual headlight mod. This mod was written up by bd43 from the FZ6-forum.com forum. This is his write up, pictures and instructions.

The actual forum posts are here. I HIGHLY recommend you read them!

http://www.fz6-forum.com/forum/how-tos/1663-bd43s-07-headlight-mod-part-1-a.html

http://www.fz6-forum.com/forum/how-tos/1666-bd43s-07-headlight-mod-part-2-a.html

Make the harness in part one!! Or contact bd43 to purchase a pre-made harness that he makes!

Remove the battery and the airbox. Remove the two 10mm bolts that hold the battery box in place and slide the box rearward. The connector is hidden in a rubber boot just inside the frame.

Unclip the connector halves apart. The bottom female connector in this picture goes to the left handlebar switch while the upper male connector runs off to various circuits on the frame as controlled by the switch.

Feed the pin side of the wire harness, made in Part 1, through the frame, into the boot. This picture shows the fabricated pin to a factory stock one. It's an exacting match.

Note the position of the green low beam wire from the left handlebar switch connector. It is 3rd left on the bottom row of wires in this picture. Determine the location of this position on the male frame side connector. It should be an empty location. Note this because that is where the fabricated pin will be inserted.

Insert the fabricated pin into the empty slot in the frame male connector. Observe how the other pins have been inserted in this row and ensure the fabricated one is inserted the same way. This ensures that the pin locks into place. Check to ensure that it holds and not pull out easily.

Here is another pic of the pin inserted. It's located 3rd from the left on the bottom row. Connect the two halves of the connector back together.

Route the wire harness to the right headlight assembly anyway you like through the inside of the fairing. I chose to pass through existing fasteners. Note the purpose of the FLEXO? Probably not needed but makes it look professional.

As the same in the other headlight mods, pull the connector off the rear side of the right headlight assembly. Flip open the rear cover and insert the flag connector into the empty spot. Close the cover, fold the wire around to align with the other wires and wrap with electrical tape up as far as you can go. Plug back into headlight assembly.

Start putting everything back together. Put the connector halves back in the boot, tuck inside the frame, move the battery box back into position, and install air box on top. Note the special bolt used to hold down the battery box.

The test. Picture shows switch on low beam, the right side headlight (picture left) is illuminating low beam filament.

The switch is now flipped to high beam. The right side headlight (picture left) high beam filament is illuminated while the low beam filament is now off or non-illuminated.

That concludes the mod. Once the wire harness was made, not a lot of time was spent on the bike itself. Hopefully this is of use to someone.

Update: To date, this mod has been installed in all bikes around the world from years 2004 to 2008 inclusive. That's a question I get asked a lot, "does it fit in a 20XX bike?", and the answer is "yes". Happy riding and ride safe.

-BD43