Kawasaki Forums - Dual Headlight Mod for 03-05 ZX6R/RR & 04-05 ZX10's by speedracer138

Well I finally got all my info together to do the Dual Headlight Modification Post. This mod allows you to have 2 low beams on and when you switch to Hi Beams, The low beams go off and @ Hi Beams come on. I use the stock headlight harness and if yiu're a little electro-mechanically inclined, won't have any problems performing this mod.

What You'll need:

Tool:
Wire cutters, Crimpers, Needle Nosed Pliers, Aviation tin snips (LH cut), Ruler or tape measure, Heat Gun & Soldering Iron.

Supplies:
18 AWG wire, Electrical tape, Rosin Core Solder, Various size heat Shrink tubing (1/4, 1/2, & 1 ").

Parts:
5 Female spade connectors, 3 10-12 AWG wire Splice Crimps, 6 flag female terminals, 2 H4 plugs or 2 H4 sockets with side exiting wires and 2 60/55 watt H4 bulbs (Your choice e.g. silver star, PIAA, OSRAM etc.), & 1 Standard 5 post Bosch type relay with harness connector.

To do this mod, it would be easier with the headlight removed from the bike but can be done with it installed.

First step is to get access to the headlight wire harness. Remove the inner fairings (Another Post) and the round headlight bulb covers. Disconnect the headlight harness from the main harness and unplug the LH turn signal connector. At this time you can choose to do this with the headlight assembly installed or remove it from the bike. The Upper fairing will require removal to accomplish this task. Unplug the H7 headlight bulb connectors and carefully extract the headlight wire harness from the housing. On the 05-06, there is aplastic retainer that hold the wires secure. Just pull the wires between the gap at the retainer and it will come out. You may have to help route it thru the housing to get it out through the grommet hole.

After the harness is out, remove the electrical tape forward of the grommet and cut all 3 wires to the same lengthat the factory black wire crimp. Now pull the wires thru the grommet (this will take some working, tugging & pulling) freeing it from the bonding glue. Try to prevent tearing the grommet holes. You should have 3 clean holes thru the grommet.

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Next, cut the 18 AWG wire to the following lengths for all ZX6R/RR's: 4 each, 9 inches; 1 each, 8 inches; and 1 each, 10 inches.
Also 3 each, 4 1/2 inches for 03-04 ZX6R/RR's & ZX10's or 3 each, 13 inches for the 05-06 ZX6R/RR's. Strip approximatel 1/2" from one end of each wire. Twist the stripped ends of the two 9" long wires together, then the other two 9" wires together and the 8" and the 10" wires together and install the 10-12 AWG splices & crimp them on securely. Next, take the other 3 wires (depending on which bike you have) and pass them thru the grommet. Strip the ends and crimp them to the 3 pairs of wires already crimped. Using a blue and pink paint marker, mark the short 8"and long 10" pair of wires blue and one of the pair of 9" wire in the same crimp pink (Yeah, I know PINK?; I chose these as they are the stock harness colors)

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Arrange the wire so that the Lt blue wires are on top, the pink wires on the RH side and the unmarked Black wires on the LH side in the grommet holes viewed as you're sitting on the bike. Make sure that both ends of the same wire are marked the same color. The long Lt Blue wire will go to the RH headlight and the short Blue to the LH Headlight. One each of the Pink and Black wil go to each side headlight. Now crimp and solder the Flag terminals to the ends of the six headlight wires.

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Oh, I forgot one step: Before Crimping and soldering the flag terminals, install some heat shrink over the splices and each trio of wires going to each LH & RH side headlight. Or you can use electrical tape; This will make a neat installation. Next, strip the other 3 wires and crimp the female spade terminals on ONLY the 2 Pink & Blue marked wires. Now, strip the stock wire ends and crimp the female spade terminals on ONLY the 2 Pink & Blue marked wires. As for the Black wires, twist them together and crimp a female spade terminal to them. You can install some split flex tubing, heat shrink or electrical tape over the wires if you want. You 05-06 harness should look similar to the following picture. Next, Get the relay connector harness and remove the wires from it and put aside with the relay.

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The pictures above in part 4 show almost complete 05-06 harness, the middle pic is an 03-04 complete harness and the bottom pic shows a complete 05-06 harness. The H4 connectors aren't shown. Now the H4 bulb Mod. You'll need a pair of LH cutting tin snips. You can use straight snips also. Cut the bulb metal base flange as shown in the picture below. Make sure that the Top contact male spade is horizontal and one each contact spades are vertical on each side. Like an upside down "U". The locating tab should be on top. same as the horizontal spade connector. Once that's done, test fit them into the H7 locations. Trim as necessary. Now you can route the wires thru the grommet hole and to the headlight locations. It helps to tape the ends together and remember that the longer blue marked wire goes to the RH headlight. The grommet just pushes into place; push in the cenet and it will pop in. Install the Flag terminals in the H4 plastic connectors, install the bulbs and secure them with the clip, then plug in the connector. Leave the round Covers off for now.

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Part 6 of Dual Headlight Mod: Continued from Part 5

Okay, Now it's time to plug the wires into the relay socket/ plug. Please follow the Schematic below to avoid any problems. Once the relay wires are connected, plug in the relay and secure the relay according to the year of the bike. The 03-04 ZX6R/RR's & 04-05 ZX10's relay is pushed in the little cavity next to the grommet. On the 05-06 ZX6R/RR's, the relay is secured to the little "Nipple" that sticks out above the RH round bulb cover using a automotive trim "Tin nut" or ?.

Now you can install the headlight assembly, plug in all the removed connectors and test out your lights. Or you can install the running lights at this time; (another "DIY" post) Re-install the headlight and fairings in the reverse order it was removed. Check all you connections to make sure they are secure and that none of the wires are pinched or in the way of the fo