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DIY:Twin headlight beam for Fazer

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  • DIY:Twin headlight beam for Fazer

    Hi friends

    Up with a new DIY. A friend of mine recently got a new Yamaha Fazer and as usual didn't like the single low beam and High Beam. So he wanted me to get the beams work togethter.

    Planned it to be a simple DIY and went for it and it was a great sucess

    What you will need:

    1.Allen key set
    2.Wire stripper
    3.Insulation tape
    4.Some good quality wire

    Lets start up:

    1.First you need to remove both the side fairings.There would be 2 black allen screws on the top,one on the side and last one on the bottom.Then comes the little difficult part.The side fairing is somewhat clipped to the dash.just need to pull it little hard.

    2.Next you have to pull it like you do with the side sheilds.



    3.Then comes the wiring part.Lets start from the left side.

    4.The headlight bulb holder and pilot lamp will connect to a socket plug found on the left side where you opened the fairing.

    5.In the holder of the bulb there will be two wires and you would be left with an empty opening.Thats where you need to insert the new wire.I just pushed the stripped end of the wire inside the holder.You will now have to connect the other end of the new wire to the wire of the high beam line.Its the yellow colour wire.(Refer pic)



    6.You need to repeat the same procedure for the right headlight.The low beam for the right side must be connected to the green wire.

    7.Finally secure the connected wires with insulation tape.

    8.Close the fairings


    ''09 Hero Honda Splendor
    '13 Bajaj Pulsar 220
    '17 KTM Duke 390

    www.facebook.com/harikishen

  • #2
    Re: DIY:Twin headlight beam for Fazer

    DIY Approved
    Biking is not about what you have between your legs, its all about how well you use it!!!!!!!

    Give your details here if you want to help your fellow xBhpian stranded in your city

    Touring Blog: Cycling in Mongolia!

    Comment


    • #3
      Re: DIY:Twin headlight beam for Fazer

      Nice, but why not use a relay for avoiding battery drain? Or else, one can upgrade to a bigger battery too!
      Got a $5 head? Get a $5 helmet.
      Because everyone who passes, isn't a martyr!

      Bullet Service Guide CBR 250R Parts Manual Fz16 service manual - https://drive.google.com/file/d/0B1-...VFQmJzakk/view
      Hero Moto Corp Bikes' Parts RE STD 350 Wiring Diagram (CI) Service Manual - Classic 350/500
      ZMR parts - https://drive.google.com/file/d/0B-U...it?usp=sharing
      P200NS Spares' prices - https://docs.google.com/spreadsheet/...taGd5R2c#gid=0

      Comment


      • #4
        Re: DIY:Twin headlight beam for Fazer

        Originally posted by Divya Sharan View Post
        Nice, but why not use a relay for avoiding battery drain? Or else, one can upgrade to a bigger battery too!
        I don't think it will need a relay since friends would be using it to a maximum of 2 hours at night

        Sent from my GT-I8552 using Tapatalk
        ''09 Hero Honda Splendor
        '13 Bajaj Pulsar 220
        '17 KTM Duke 390

        www.facebook.com/harikishen

        Comment


        • #5
          Re: DIY:Twin headlight beam for Fazer

          I have done it earlier and used a bit different method.. Got new h4 holders of the same make as stock (minda i guess).. It comes with shielded wiring nd just removed old holder nd fixed new one at fixed wiring just like original. Battery is fine till now. Had problem only once bcz of acid leak from battery. Got refilled and my bike starts on first button pish even after 4 5 days of rest in cold..

          Comment


          • #6
            Re: DIY:Twin headlight beam for Fazer

            how to light up both lights. in fazer?
            i recommend relay with fuse which is not demonstrated here.
            follow photo by photo. total four photo. its easy.








            2.



            3.


            4.
            Last edited by dux; 12-27-2015, 03:22 AM. Reason: image reuploaded

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            • #7
              Yamaha Fazer- Twin headlights setup.

              The Yamaha Fazer is one beautiful and menacing looking bike and an amazing performer. There is nothing really wrong with the bike (okay the mileage and top-speed could've been better) except the simply inadequate headlight setup. First of all only one light glows at a time and even then the beam spreads off the center-line making the lighting provided by this bike one of the worst. Even on a completely dark highway I had problems with the lights and had to stay ahead of my friends CBZ Xtreme to be able to see properly. One way to make this situation a little better is to make both the lights glow at the same time.
              This way you will have two beams (still without a good spread) but you do get more illumination. In this thread I will describe the steps required to get both the lights working. In the Fazer both the lamps are exactly the same so they both have both low and high beam filaments. The high-beam filament is not connected on the left side and the low-beam filament is not connected on the right side. What will be doing electrically is we connect connect the unconnected filaments with the corresponding filament on the other lamp.

              Precautions:
              Doing this can void the electrical warranty of the bike so you will have to take this risk.
              Also improper wiring can result in a shock and also might burn the bikes fuse. So make sure you are following the steps exactly. If you are not comfortable making electrical connections then you can ask a friend for help. This also requires the use of sharp tools like a blade. Use caution while working with these. This setup will put additional strain on the battery so its best to switch the lights on after the engine has been started once you have done this mod.

              Tools Required (dont have a picture of all the tools, but they are quite easy to get):
              1. Cutting pliers
              2. Blade
              3. 4mm Allen key (also called Hex key or Allen wrench)


              Other items required:
              1. Lug connectors. They look like this and you can get them at an automobile spares shopClick image for larger version

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              2. Electrical wire. Make sure they are at least as thick as the wires going to the headlights in your bike.
              3. The electrical wiring harness going to the headlamps. Its the part which connects using a white connector inside the fairing on the left side of the bike. Its called the Cord Assembly in the Yamaha parts manual and you can get it at the SVC spares shop. You can also use the one present in your bike but having an extra one ensures that you have a fallback one if something goes wrong.
              4. Electrical insulation tape.


              Steps:

              1. First you have to prepare the lug connectors with the wires. To do this open up the ends of the lug connector using the pliers and flatten it down till it looks like this.Click image for larger version

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              2. Then remove the insulation from one end of the wire and place it on the flattened end of the lug connector. Like this.Click image for larger version

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              3. Now fold the end of the lug connector over the insulation of the wire so that connector gets attached to the wire perpendicularly. Its easier to do this by first folding the lug enough that the wire can just fit in and then finally slipping the wire in and pressing it so that it grips.
              4. Then wrap the bare wire over the neck of the lug so that a proper electrical contact is formed.
              5. Open the flap of the black plastic blocks of the cord assembly and insert the lug connector in the empty slot. If you are facing the backside of the plastic connector then either the top or the right slot will be empty. The right slot will be empty for the left side connector(low-beam, with the shorter wire) and the top slot will be empty for the right side headlight (high-beam).After inserting the lug connector it would look like this (for the lug inserted in the top slot of the right side plastic connector)Click image for larger version

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              6. Do the same using another lug and wire for the other black plastic connector on the cord assembly. This lug connectors will make contact with the terminals of the lamps.
              7. Remove the black covering tape from the lower part of the cord assembly. The part which has the white coloured connector. This will expose all the wires and make cutting the wire insulation easier.
              8. Now we need to connect the wires. The wire you added to the longer side plastic connector will connect to the non-ground wire of the left side plastic connector. This wire is green in colour. Cut out a portion of the insulation on the green wire and then join the wire from the longer side plastic connector here. This connects the low-beam filament on the right side with the low-beam filament on the left. This is how it should look.Click image for larger version

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              9. Now connect the new wire on the shorter side plastic connector to the yellow coloured wire. This connects the high-beam filament on the left side with the high-beam filament on the right.
              10. Cover the new connections with insulation tape and then put back the insulation tape that you removed or you can use fresh insulation tape over it. This is how it would look. Click image for larger version

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              11. We now have to replace the harness on the bike with this custom one we made. Remove the black coloured plastic pieces below the handlebar using the the allen key and a screwdriver. Then use the allen key to undo the screws on the left and underside of the left side fairing. Then gently pull on the left side fairing back till it comes out. Now the whole left side of the bike is open to access making the process of replacing the cord assembly much easier.
              12. Make sure the ignition is off and then remove the white coloured connector coming from the bike mains first. Then remove the red connector of the pilot lamp and then pull out the black connectors of the headlamps.
              13. Put the custom cord assembly in exact reverse order i.e. headlamp connectors first, then pilot lamp and finally the white connector to the bike mains.
              14. Check that the setup works by switching on the engine and then verifying that both the headlamps light up in both low and high beams. Click image for larger version

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              15. If it works, then hooray!! Put back the fairing panels and you are done!!


              Take a test ride and adjust the height of the beam as per your preference. Enjoy the far improved illumination!!
              Please let me know if there are any errors in these steps.
              Your pair of feet can tire you... Your pair of wheels can never tire you...

              Comment


              • #8
                Re: Yamaha Fazer- Twin headlights setup.

                Originally posted by arijitmaniac View Post
                The Yamaha Fazer is one beautiful and menacing looking bike and an amazing performer.

                ...........
                Take a test ride and adjust the height of the beam as per your preference. Enjoy the far improved illumination!!
                Please let me know if there are any errors in these steps.
                Approved and merged!
                Got a $5 head? Get a $5 helmet.
                Because everyone who passes, isn't a martyr!

                Bullet Service Guide CBR 250R Parts Manual Fz16 service manual - https://drive.google.com/file/d/0B1-...VFQmJzakk/view
                Hero Moto Corp Bikes' Parts RE STD 350 Wiring Diagram (CI) Service Manual - Classic 350/500
                ZMR parts - https://drive.google.com/file/d/0B-U...it?usp=sharing
                P200NS Spares' prices - https://docs.google.com/spreadsheet/...taGd5R2c#gid=0

                Comment

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