919 and 599 headlight swap? - Wrist Twisters
 
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post #1 of 11 Old 10-29-2014, 06:49 AM Thread Starter
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919 and 599 headlight swap?

Is it possible to put a '06 599 headlight on a '07 919? I'm thinking the 599 headlight will fit on the 919 but it looks like the 599 has two bulbs and the 919 has one. Anyway to make this work? I'm no electrician...

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post #2 of 11 Old 10-29-2014, 07:02 AM
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post #3 of 11 Old 10-29-2014, 07:11 AM Thread Starter
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Yeah I searched for the search bar. You know the one with the little magnifying glass... the one that isn't there. Just saw it in the middle of the tool bar.

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post #4 of 11 Old 10-29-2014, 07:33 AM
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I have a 599 headlight on my 919. Its OEM build quality and relaibility in a stylish design.

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post #5 of 11 Old 10-29-2014, 07:54 AM Thread Starter
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Yeah I was just reading thru the older tread about the swap. Is that how you swapped yours Heli?

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post #6 of 11 Old 10-29-2014, 08:12 AM
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Yeah pretty much .... but I wired it up myself (like ROB-T described) so when you turn on the high beam the low beam stays on all the time. Great light output and has been issue free for a few years now.

- Wire the low beam (with a inline fuse) into the "key on hot" side of the ingnition key harness .... on the bike side of the harness so that if you have to switch out ignition key unit you won't have to mess with the headlight again.

- Wire the high beam into the original high beam trigger wire.

- Use the ground from the orignal hadlight wiring for both.

Orignally with the OEM 919 headlight when you hit the starter button the headlight cuts off dirrecting all available voltage to the starter .... if you wire it as described above you will lose this feature .... I have not had any problems with my set up like this.

You will also need to use a few washers stacked up under the headlight brackets as a spacer. The 599 bucket is wider so the 919 mounts need to be spaced out a touch to make it all jive together. Also make sure to solder and heatshrink everything and turn the bars a few times to mek dure your wire routing is smooth and issue free.

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post #7 of 11 Old 10-29-2014, 08:15 AM Thread Starter
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Awesome! Thanks.

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post #8 of 11 Old 10-29-2014, 09:09 AM
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The hardest part is fitting the wiring harness and connectors into the 599 bucket, it takes some time to get everything in it without being in the way.
I used velcro on some of the connectors and stuck them to the inside of the bucket to keep them in place. Don't try to force the housing into the bucket.

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post #9 of 11 Old 10-29-2014, 09:56 AM
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Quote:
Originally Posted by HeliMech View Post
Yeah pretty much .... but I wired it up myself (like ROB-T described) so when you turn on the high beam the low beam stays on all the time. Great light output and has been issue free for a few years now.

- Wire the low beam (with a inline fuse) into the "key on hot" side of the ingnition key harness .... on the bike side of the harness so that if you have to switch out ignition key unit you won't have to mess with the headlight again.

- Wire the high beam into the original high beam trigger wire.

- Use the ground from the orignal hadlight wiring for both.

Orignally with the OEM 919 headlight when you hit the starter button the headlight cuts off dirrecting all available voltage to the starter .... if you wire it as described above you will lose this feature .... I have not had any problems with my set up like this.

You will also need to use a few washers stacked up under the headlight brackets as a spacer. The 599 bucket is wider so the 919 mounts need to be spaced out a touch to make it all jive together. Also make sure to solder and heatshrink everything and turn the bars a few times to mek dure your wire routing is smooth and issue free.
Similar in my case but since I already had a Power Distribution Module, I have one light on one circuit (Hi in my case) always ON and both light Ground controlled by the Hi-Low switch on a separate switch.

Quote:
Originally Posted by 2007BruteForece View Post
The hardest part is fitting the wiring harness and connectors into the 599 bucket, it takes some time to get everything in it without being in the way.
I used velcro on some of the connectors and stuck them to the inside of the bucket to keep them in place. Don't try to force the housing into the bucket.
I also pulled some of the main harness out of the 919 bucket to make space for the 599 connector.

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post #10 of 11 Old 10-29-2014, 11:22 AM
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Quote:
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I also pulled some of the main harness out of the 919 bucket to make space for the 599 connector.
Same here. Rob's write-up is great if you want to wire it together yourself. For me, I wanted plug and play so I could revert back to stock at a moment's notice so I got the eastern beaver harness. One unfornseen advantage of using the harness was that I was able to pull out more of the plugs on the main harness in the bucket and reroute them to the inside the neck where the pairs valves normally are (i removed them). This gave me more room to work with bit the space in the bucket is still a major pain in the ass to say in the least. In the 599 headlight thread, iirc, I put a picture there that shows how I routed the remaining harness to make the bucket fit.

Whatever you do, do not force it! You'll just split the bucket. Don't ask me how I know...

One last thing, some people have upgraded their bulbs/sockets. This is on my to do list, but been putting it off for a few years now because dealing with the harness is that much of a pain in the ass. If you want to do the bulb upgrade, do it all at once would be my suggestion.

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post #11 of 11 Old 10-29-2014, 01:41 PM
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I've got the Eastern Beaver harness for my conversion too, I opted to get their 3cs power adaptor at the same time, now just need to find a couple days of not being able to ride so I can get it all installed


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