headlight mod "how to"

[Charlie-brm]

I'm planning on doing it this Winter.  I have what will probably be my last ride of the Season coming up in a couple weeks and have plenty to do from now to then - Pat's insight was a life-saver - but after that I'll take her shirt off and brighten up her candles.

Meanwhile, maybe try spraying some electronic contact cleaner into the gaps between the button and the housing and with the key off, work the switch repeatedly until it's reliably recovering all the way out every time. My switch got stuck half in - half out, four years ago. Three or four shots of contact cleaner with the little red plastic tube to concentrate the squirts and I haven't had to give it a thought ever since.

[ct7088]

Try using LPS-1 it softened up the dirt enough to wipe the contact surfaces clean. Switch has worked for two years also worked for the turn signal switch. A single 40 amp relay used as a bypass of the main switch battery circuit cures headlight and coil voltage supply problem. My headlight is bright(as a standard bulb can be) all the time and the turn signal never makes the bike die at a intersection.
Chris

[Jeff0308]

Does the headlight relay make a lot of difference as far as brightness goes? If so how much?  %
I thought the FJ already had a headlight relay. I turn on the light switch and hear a "click" which sounds like a relay.  Never bothered to investigate it though.

[Charlie-brm]

The difference is going to depend on how much power you are losing at the moment. It's even possible you are not losing much at all. Getting familiar with a voltmeter will eliminate some guess work. With a voltmeter to compare the voltage directly across the battery to any voltage else where on the motorcycle will clue you in. e.g. I found that the leads at the headlight socket were 2 volts lower than what was at the battery. This pic can give some idea of what that translates to with before and after, inside a workshop with the rest of the shop lights turned off. That is with a standard halogen bulb and the distance to the door at the back wall is about 25 to 30 feet (It's been several years now - I'm estimating).

[Jeff0308]

Where is best to mount the headlight  relay.? Around the battery area?

[FJmonkey]

Where is best to mount the headlight  relay.? Around the battery area?

That is one of the good things about adding relays. Put them where you can access them if things stop working. They tend to be very reliable but they can fail. Make testing easy and quick. The battery area is a great place once the air box is out and pod filters are in.