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badboyjcs

2007 Headlight wiring for dual-sport

8 posts in this topic

Has anyone re-wired their bike to use the high beam and low beam? If so how did you do it?

Working on it. I've purchased a Baja Designs type switch cluster for the handlebar with all the standard functions (Hi/Lo Beam, turn signals, horn, kill switch). I'm waiting (I was told 2-3 weeks) on an order of OEM connectors/pins/crimping tool ($$$) so I don't have to cut/splice any wires. Everything will be plug/play/quick disconnect. Should have it done in a month.

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Have you test fitted your turn switch? I had problems finding one that fits without having to modify the hot start lever.Ifound one on e-bay that worked without any mods.

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Have you test fitted your turn switch? I had problems finding one that fits without having to modify the hot start lever.Ifound one on e-bay that worked without any mods.

I'm will be using two spacers and longer bolts to lift the hot start lever up to clear the cluster. The pics attached will give you an idea of what I'm talking about. I used a a couple of spacers and bolts I had in my nuts/bolts collection to see what it would look like. I'll be replacing them with shorter spacers and proper allen head bolts.

http://img.photobucket.com/albums/v177/samirpowar/07%20WR450/DSC07713.jpg

http://img.photobucket.com/albums/v177/samirpowar/07%20WR450/DSC07712.jpg

http://img.photobucket.com/albums/v177/samirpowar/07%20WR450/DSC07711.jpg

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Hell I bought a hi/low/off switch from the local hardware store and wired it up to the high low of the HL's. I decided to use separate HL's for high and low, but regardless of how you do it it will work.

Easiest way to wire it is to wire each of the hot leads from the HL (mine were halogen so polarity mattered - had a hot lead and a ground) to each pole of the Hi/low switch. Then, run your hot lead coming off of the stator to the center terminal of the switch. Finally, ground the black wires of the headlights to somewhere on the frame.

FYI this was for an AC setup from a 99, so it shouldn't necessarily be the same for your bike (DC, right? ...don't keep tabs on them newfangled ones...).

haha so this might not have been any help to you at all... :lol:

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Hell I bought a hi/low/off switch from the local hardware store and wired it up to the high low of the HL's. I decided to use separate HL's for high and low, but regardless of how you do it it will work.

Easiest way to wire it is to wire each of the hot leads from the HL (mine were halogen so polarity mattered - had a hot lead and a ground) to each pole of the Hi/low switch. Then, run your hot lead coming off of the stator to the center terminal of the switch. Finally, ground the black wires of the headlights to somewhere on the frame.

FYI this was for an AC setup from a 99, so it shouldn't necessarily be the same for your bike (DC, right? ...don't keep tabs on them newfangled ones...).

haha so this might not have been any help to you at all... :lol:

The headlight and ignition system are AC, everything else is DC.

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