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General Category => Modifications => Topic started by: Perez on October 13, 2010, 10:43:05 AM

Title: Headlight Mod
Post by: Perez on October 13, 2010, 10:43:05 AM
Because of its unique size & shape, I assume there is not an upgrade to the headlight bulb for even more wattage short of a relay mod that I saw that looks like it just drives more voltage and current to the existing bulb....not a great idea for bulb life.

Anything else?
Title: Re: Headlight Mod
Post by: Fred on October 13, 2010, 10:49:00 AM
Because of age and wire size there tends to be less than 12 volts at the head lamp, so the relay mod should not effect  bulb life. There are higher wattage bulbs available, but with the low voltage it might not be as much of an improvement as you would think. also get carried away and you might melt stuff. Or.... you could get one of those trick HID setups.
Title: Re: Headlight Mod
Post by: Perez on October 13, 2010, 10:53:10 AM
Any idea what the stock wattage is and where to get a higher wattage bulb?
Title: Re: Headlight Mod
Post by: Fred on October 13, 2010, 10:58:02 AM
55/60 I think? Its in the manual. Almost any on line purveyor of motorcycle parts can set you up.
Title: Re: Headlight Mod
Post by: Perez on October 13, 2010, 11:10:36 AM
I have a rather basic understanding of electricity.....how does adding a relay incease the volatge sent to the bulb? A relay is nothing more than an electric switch. Apply voltage/current to these terminals and a switch closes.....
Title: Re: Headlight Mod
Post by: Pat Conlon on October 13, 2010, 11:24:40 AM
No problem, here read all about it:
http://www.webbikeworld.com/t2/headlight-relay/motorcycle-headlight-relay.htm (http://www.webbikeworld.com/t2/headlight-relay/motorcycle-headlight-relay.htm)

Short answer: It's the large wires that you run to your battery which provides the additional voltage to your light.

Cheers!
Title: Re: Headlight Mod
Post by: Fred on October 13, 2010, 11:31:26 AM
It doesn't increase the voltage. You are correct in thinking of it as a switch. What the mod does is eliminate the voltage that is lost in the stock wire harness, by running a direct hopefully larger wire from the battery to the headlamp. The relay uses the signal (voltage) from the wire harness to control the new circuit that was created when the new wire was installed from the battery to the headlamp. So all your switches work as they always have without the voltage drops that occur when running through all the original components.
Title: Re: Headlight Mod
Post by: Pat Conlon on October 13, 2010, 11:47:16 AM
Quote from: Fred on October 13, 2010, 11:31:26 AM
It doesn't increase the voltage...... What the mod does is eliminate the voltage that is lost in the stock wire harness, by running a direct hopefully larger wire from the battery to the headlamp. 

Uh, yea,.... The net effect of the mod is that you have increased the voltage to your headlamp....
Title: Re: Headlight Mod
Post by: Perez on October 13, 2010, 12:18:10 PM
Not to belabor the point, but I was looking at the wiring diagram in the 'modofications' section and it shows TWO relays.
Do I need two relays, or is that second relay and the secondplug shown for a second lamp?
Title: Re: Headlight Mod
Post by: Fred on October 13, 2010, 12:20:05 PM
Quote from: Pat Conlon on October 13, 2010, 11:47:16 AM
Quote from: Fred on October 13, 2010, 11:31:26 AM
It doesn't increase the voltage...... What the mod does is eliminate the voltage that is lost in the stock wire harness, by running a direct hopefully larger wire from the battery to the headlamp. 

Uh, yea,.... The net effect of the mod is that you have increased the voltage to your headlamp....

Not to split hairs but the mod eliminates a voltage loss, while this means there is effectively increased voltage at the headlamp, it is not more than the 12 volt for which the headlamp was designed, which I took to be a concern from the original post. If I have read more into the question than I should, I humbly apologize and now return to my corner to work on reducing my use of run on sentences. :flag_of_truce:
Title: Re: Headlight Mod
Post by: Perez on October 13, 2010, 12:26:27 PM
Can I wire the proposed setup using just 1 relay if I just want to brighten the existing bulb?
Title: Re: Headlight Mod
Post by: mikeholzer on October 13, 2010, 12:31:16 PM
Quote from: Perez on October 13, 2010, 12:26:27 PM
Can I wire the proposed setup using just 1 relay if I just want to brighten the existing bulb?

The second relay is for the high beam. Incidentally, the wattage of a standard H4 halogen is 55W low beam/60W high beam. The bulb is available with up to a 100W high beam; a quick Google search provided many vendors with varying wattages available.
Title: Re: Headlight Mod
Post by: Pat Conlon on October 13, 2010, 12:32:22 PM
No, you need 2 relays 1) to activate the low beam and 2) to activate the high beam.
Title: Re: Headlight Mod
Post by: Perez on October 13, 2010, 12:50:48 PM
I must be having a stroke or something and I just don't realize it.
I have attached the link to the diagram I am refering to in case we are talking about 2 different things.
       [url]http://www.fjowners.com/index.php?topic=2033.0] (http://[/url)       http://www.fjowners.com/index.php?topic=2033.0
It is the attached .pdf file called: Headlight Relay Instr FJ.pdf

In the diagram TWO 3-pin headlight connectors are shown......in other words, for TWO bulbs.
I must be missing something in the way of how one is for low beam and one is for high beam.
.....on a H4 HB2 9003 bulb Low and high are all powered through ONE connector!
Title: Re: Headlight Mod
Post by: Fred on October 13, 2010, 12:57:02 PM
One is the original connector that you can plug into with spade terminals to fire the relays the other is a new connector the plus to the bulb.
Title: Re: Headlight Mod
Post by: Perez on October 13, 2010, 01:23:08 PM
I'll just buy the ready made piece online.....thanks anyway.
Title: Re: Headlight Mod
Post by: racerman_27410 on October 13, 2010, 01:56:55 PM
Quote from: Perez on October 13, 2010, 01:23:08 PM
I'll just buy the ready made piece online.....thanks anyway.


i bought a H4 Single bulb harness from these people....get the ceramic headlight plug as it will not melt if you choose to use a higher wattage bulb..... i strongly suggest still not going higher than 90 watts as high wattage bulb life sucks....  although they can and will last just long enough to melt your headlight reflector

http://easternbeaver.com/Main/Products/H4_Kits/h4_kits.html (http://easternbeaver.com/Main/Products/H4_Kits/h4_kits.html)

Kookaloo


Title: Re: Headlight Mod
Post by: SlowOldGuy on October 13, 2010, 02:09:21 PM
I'm running an 80/100 bulb for years with the headlight relay mod.    I remember Jeff having problems when he tried to run a 130W bulb (?!).  Those kept blowing out, presumably to excess heat.

I've only blown one headlight bulb in the last 10 years.

DavidR.
Title: Re: Headlight Mod
Post by: Marsh White on October 13, 2010, 02:33:34 PM
Quote from: Perez on October 13, 2010, 01:23:08 PM
I'll just buy the ready made piece online.....thanks anyway.

You might as well just buy the HID kit here: http://www.ddmtuning.com/Products/DDM-35W-55W-Single-HiLo-Motorcycle-HID-Kit (http://www.ddmtuning.com/Products/DDM-35W-55W-Single-HiLo-Motorcycle-HID-Kit)
Same price...

No need for a relay kit when running an HID setup as it draws less power.

Full thread here: http://www.fjowners.com/index.php?topic=2132.0 (http://www.fjowners.com/index.php?topic=2132.0)
Title: Re: Headlight Mod
Post by: Pat Conlon on October 14, 2010, 12:10:44 AM
Quote from: racerman_27410 on October 13, 2010, 01:56:55 PM
Quote from: Perez on October 13, 2010, 01:23:08 PM
I'll just buy the ready made piece online.....thanks anyway.
i bought a H4 Single bulb harness from these people....get the ceramic headlight plug as it will not melt if you choose to use a higher wattage bulb..... i strongly suggest still not going higher than 90 watts as high wattage bulb life sucks....  although they can and will last just long enough to melt your headlight reflector

http://easternbeaver.com/Main/Products/H4_Kits/h4_kits.html (http://easternbeaver.com/Main/Products/H4_Kits/h4_kits.html)

Hey Frank, good advice on the ceramic plug for high wattage bulbs. I bought my harness from these guys:
http://www.electricalconnection.com/wire-harnesses/hrns_headlight.htm (http://www.electricalconnection.com/wire-harnesses/hrns_headlight.htm)
I liked the plug feature on the relays that, should a problem ever occur with either relay, you can unplug them, and plug in a new one. I keep a spare relay in my tool kit.
No messing around with cutting/splicing wires. (Murphy's Law: At night, in the rain, by the side of the road)

Question: Does the  Eastern Beaver kits have this plug feature or are the relays hard wired?
In looking at their web page, I see that the Panasonic relays come with a "socket" Is this the same thing?
Cheers!
Title: Re: Headlight Mod
Post by: racerman_27410 on October 14, 2010, 12:37:52 AM
Quote from: Pat Conlon on October 14, 2010, 12:10:44 AM

Question: Does the  Eastern Beaver kits have this plug feature or are the relays hard wired?
In looking at their web page, I see that the Panasonic relays come with a "socket" Is this the same thing?
Cheers!

yes they have sockets... and the relays are smaller and more waterproof than the electrical connection harness

i had the E/C setup previously but the headlight connector failed and melted the wiring.. i believe they have updated their H4 connector now though.

KOokaloo!

Frank
Title: Re: Headlight Mod
Post by: teeeeeceeeee on October 14, 2010, 03:22:16 AM
I Have a New H4 High Output Headlight Harness by The Electrical Connection for an FJ that I never installed - It's still in the delivery box so any member can have it for FREE if you pay the postage from Australia.

It cost me US $12.30 postage from the US to Australia ??? years ago.


It has a plastic connector & yes Frank........... it's the one you recommended to me years ago that I never fitted.



Kookaloo


TeeCee  :good:

Title: Re: Headlight Mod
Post by: Perez on October 15, 2010, 06:30:42 PM
I did exactly as racerman did. I bought the eastern beaver with the ceramic plug. I think the headlight shell itself is made from plastic too....right? So that will be the weakest link as far as melting.

I ordered an 80 /85 and a 100 /105 bulb. Melting and/or bulb life are my concern. I suppose I can put it in and use the old finger test. Looks like I can get my finger right there on the base of the socket when everything is all assembled.

I wish I had known about that HID. The ones for cars are pretty pricey and in some cases reputed to have a huge current draw that melts wires, etc. I just assumed it was too expensive, so I ignored it. Silly me.
Title: Re: Headlight Mod
Post by: racerman_27410 on October 15, 2010, 08:12:59 PM
im running HID driving lights so having a full brightness halogen in the standard position is ok .

Kookaloo!
Title: Re: Headlight Mod
Post by: rodo68 on October 17, 2010, 02:34:04 AM
hey teecee is that your misses in the picture shootng an arrow, if not whats the story
Title: Re: Headlight Mod
Post by: Perez on October 17, 2010, 08:15:40 AM
racerman: how did you mount a set of driving lights without making the bike look funky....any pics?

Also, what about all the current draw of all this lighting? Battery still OK?
Title: Re: Headlight Mod
Post by: racerman_27410 on October 17, 2010, 12:30:19 PM
Quote from: Perez on October 17, 2010, 08:15:40 AM
racerman: how did you mount a set of driving lights without making the bike look funky....any pics?

Also, what about all the current draw of all this lighting? Battery still OK?


oh yes the battery is fine... the FJ makes plenty of electrical power to run everything i need. but i still use a voltage monitor to make sure i'm not going to be stranded  somewhere or overcharging as FJ's are want to do......

http://signaldynamics.com/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=56&category_id=14&option=com_virtuemart&Itemid=77&vmcchk=1&Itemid=77 (http://signaldynamics.com/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=56&category_id=14&option=com_virtuemart&Itemid=77&vmcchk=1&Itemid=77)


the HID's actually draw less power than the regular 35 watt halogen bulbs did and are easily twice as bright.

you can see mine and T Roy's driving lights in this picture

(http://i47.photobucket.com/albums/f198/Racerman27410/ECFR%202010%20Birthday%20ride/ECFR2010210.jpg)


KOokaloo!

Title: Re: Headlight Mod
Post by: Perez on October 17, 2010, 04:34:00 PM
What kind of lights are they or where did you get them?

Are they a set of miniature lamps designed for a car (I assume so because I see 2 of them)
Title: Re: Headlight Mod
Post by: FJ Flyer on October 24, 2010, 01:18:59 PM
The relay mod in the modifications section is ridiculously easy.  It was the first mod I attempted on the bike.  Definitely need a heavy duty bulb socket.  I melted two before Frank gave me a good one.  The instructions are accurate and easy. 

And its a good primer for putting relays in for horns, heated grips, etc.

Title: Re: Headlight Mod
Post by: racerman_27410 on October 24, 2010, 05:59:04 PM
Quote from: Perez on October 17, 2010, 04:34:00 PM
What kind of lights are they or where did you get them?

Are they a set of miniature lamps designed for a car (I assume so because I see 2 of them)

Mine are optilux (made by hella)

got them here on closeout then did a HID H3 retrofit in the housings.

http://www.rallylights.com/hella/Optilux_Aux_Lamps.aspx (http://www.rallylights.com/hella/Optilux_Aux_Lamps.aspx)

they dont offer the same ones i have anymore but there are many to choose from.


KOokaloo!

Frank
Title: Re: Headlight Mod
Post by: Perez on October 27, 2010, 03:03:58 PM
That must be some serious light you are throwing out there!

If I were to get a set of driving lamps like you have, I assume I'd need a toggle switch on the bars and I'd need another relay setup like esatern beaver makes?
Title: Re: Headlight Mod
Post by: racerman_27410 on October 27, 2010, 06:03:46 PM
i have a switched power distribution box and took my fused circuit from there.... i installed a lighted 2 position switch where the stock reserve switch was on the left hand inner fairing panel (since the reserve function is basically useless anyway)

relays are good.... they take all the load off the switchgear.

Kookaloo!


Frank
Title: Re: Headlight Mod
Post by: Perez on October 29, 2010, 10:39:35 AM
Follow up: I just put one of them Eastern Beaver relay setups along with an 80/85 W bulb in mind and its (I'm guessing) 2X brighter. I was too chicken to go for the 95/100W bulb. I gave the 80/85 the 'finger test' .....let it run for @ 5 minutes and put my finger on the back of the socket to see if it was getting hot. It was slightly warm, thats about it. Cannot say how much hotter it will be on a 90 degree day but I don't think ambient temp has much of an effect on something like this. And as far as wind and airflow go, you want to plan for the worst case scenaio.....none.

Conclusion: 80/85 bulb driven by a relay works nice. Seems 2X brighter. No overheating.
Title: Re: Headlight Mod
Post by: nchattaway on December 17, 2015, 07:52:50 AM
Quote from: teeeeeceeeee on October 14, 2010, 03:22:16 AM
I Have a New H4 High Output Headlight Harness by The Electrical Connection for an FJ that I never installed - It's still in the delivery box so any member can have it for FREE if you pay the postage from Australia.

It cost me US $12.30 postage from the US to Australia ??? years ago.

It has a plastic connector & yes Frank........... it's the one you recommended to me years ago that I never fitted.

Kookaloo

Hey TeeCee, I'll claim that free headlight relay harness offer! Happy to pay for postage to Adelaide.

Cheers,
Nathan

Title: Re: Headlight Mod
Post by: Ross1 on December 17, 2015, 08:16:11 AM
An alternative is to consider an LED headlight.
I replaced the incandescent in one of my XJ's with one from these people

http://www.cyclopsadventuresports.com/led-headlight-bulbs.html (http://www.cyclopsadventuresports.com/led-headlight-bulbs.html)

Beam is a bit more scattered than the incandescent, but I live in deer country, so it's not a bad thing.
VERY bright. Noticeable even during the daytime.    Mine is 25/55 watts, but I think that they've improved the product since last summer.
Title: Re: Headlight Mod
Post by: Neoday2 on December 17, 2015, 12:15:37 PM
Quote from: Ross1 on December 17, 2015, 08:16:11 AM
An alternative is to consider an LED headlight.
I replaced the incandescent in one of my XJ's with one from these people

http://www.cyclopsadventuresports.com/led-headlight-bulbs.html (http://www.cyclopsadventuresports.com/led-headlight-bulbs.html)

Beam is a bit more scattered than the incandescent, but I live in deer country, so it's not a bad thing.
VERY bright. Noticeable even during the daytime.    Mine is 25/55 watts, but I think that they've improved the product since last summer.

Is it the H4 bulb for our FJs?  A quick search online and that is what I found, just want to see what you went with @Ross1
Title: Re: Headlight Mod
Post by: FJmonkey on December 17, 2015, 12:25:06 PM
It is the H4 bulb/socket.
Title: Re: Headlight Mod
Post by: Pat Conlon on December 17, 2015, 12:57:00 PM
I'm going to retrofit the bulb in my '84 with a fanless H4 version (I don't want or trust moving parts)
http://www.xenondepot.com/H4-LED-motorcycle-headlight-kit-p/h4-led-mhl.htm (http://www.xenondepot.com/H4-LED-motorcycle-headlight-kit-p/h4-led-mhl.htm)

In the above link there's a comparison between the Phillips LED diode vs the CREE China LED.

Although 3800 lumen output on the new generation CREE LED vs 2500 on the Phillips LED is a significant difference
Title: Re: Headlight Mod
Post by: Ross1 on December 17, 2015, 09:09:09 PM
         I have the "CIL-LEDMD-H4 3800 Lumen H4 LED Headlight bulb" on the XJ900 which is ridden regularly. 
      Looks like they have a new and improvedproduct for 2016.
They gave me a 10% off coupon, because they were out of stock when I called to order.
     Within a week the unit was shipped (way before they told me the new shipment was expected) and still honored the discount.
Very courteous on the phone.
                It came with two circular spacers (to narrow the beam and modify the side-scatter). Spoke with one of their techs. He suggested that I could, by using longer screws, install both spacers and narrow the beam considerably. I used the larger of the two, with satisfactory results.
             Coming home at dusk that first evening after installing, the side scatter illuminated a four-point buck in the brush along the road. Slowed down quickly and simultaneously hit the horn. (This is very near where I had to dump my 750 and slide under a six-pointer a couple years ago. Still have the helmet with the hoof marks.)
         So, whatever the source, MORE LIGHT is good.
        Being new (a couple of weeks) to the FJ1200's torque, I'd be happy with flood lights pointing down the road in front of me.    
Title: Re: Headlight Mod
Post by: ribbert on December 18, 2015, 12:32:16 AM
Quote from: Pat Conlon on December 17, 2015, 12:57:00 PM
......I don't want or trust moving parts......

........then buy a Harley and wait a week.

Noel
Title: Re: Headlight Mod
Post by: TexasDave on December 18, 2015, 02:22:50 AM
Quote from: ribbert on December 18, 2015, 12:32:16 AM
Quote from: Pat Conlon on December 17, 2015, 12:57:00 PM
......I don't want or trust moving parts......

........then buy a Harley and wait a week.

Noel
Those Harley parts keep moving-- just very sloooowly.   :blum2:   Dave