Installing Dual Headlights - Wrist Twisters
 
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post #1 of 15 Old 03-21-2009, 02:56 PM Thread Starter
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Installing Dual Headlights

Here's my take on installing Dominator Dual Headlights :

After reading the forum on the subject I've landed on some of robtharalson's post on how the dual headlight setup would damage the starter switch in the long run... here's a link to one of his posts : https://www.wristtwisters.com/forum/s...1&postcount=13

So, I've contacted him A BIG THANKS TO rob and we came up with this circuit :

I have put a cap on the ground coming from the headlight connector to ground the circuit directly on the battery not to load the existing circuit.

With this setup - as previously mentioned - you put the load directly on the battery and not on the existing circuit... you actually only put the load of the relays on the existing circuit.

If you need help understanding how a relay works here's a good link : http://www.r1200gs.info/howto/relay.html

The wiring of the dominators is not the same as the harness from the bike :



919 harness - Dominator - Function
Green = Black = Ground
Blue = Yellow = High Beam
White = White = Low Beam

The wiring of the running lights inside the headlight assembly doesn't have the same color code either

Running Light - Function
Yellow = Ground
White = Energised (+12v)

What else you will need :



To complete the circuit as shown you will need :
- two relays
- 2 battery connectors
- 2 female insulated connectors
- 2 male insulated connectors
- some shrink wrap
- 1 inline fuse holder
- 1 25 amp fuse (maybe less but that's the one I used)

Now that you have everything you will need to complete the circuit as shown, you can put the relays inside one of the headlight assembly, yup it fits with a bit of a headache.... or you can put 1 in each of them.


Once the headlight circuit is done and the +12v and the Ground have their connectors :
(Side note : I used 1 male and 1 female for the ground and +12v from the headlights to be sure not to mix them up when I wire them with the battery)

- Prepare a length of red wire with the inline fuse holder with a battery connector on one end and a male or female connector on the other end (depending on the one you put on your circuit)

- Prepare also a length of black wire with a battery connector and a connector on the other end.

- Run the wires from the battery under the tank (following the main harness to the front of the bike) and zip tie them in place. - To move/lift the tank loosen the 10mm nut and bolt.
For the fuse holder find a good place near the other fuses and attach it with a tie-wrap or double-faced tape.
At the same time pull back some of the main harness under the tank


The last thing you need to do is change the 2 bolts that hold the headlight bracket for longer ones and add a few shims to space them out so the wider assembly can fit. (you need to spread them approximately half an inch to 3/4 of a inch in total.

Mount the lights while tucking in the wires and bolt everything and connect your 2 wires with the ones from the battery and your done !


You can see one of the connectors.. I just didn't hide it yet.. because the ground and +12 are different I can just tape them up to help hide them and not worry about mixing them up !

Next project : mounting the windshield for it.

Simon
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post #2 of 15 Old 03-21-2009, 05:10 PM
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Nice job Sarge! Headlights look great on the bike

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post #3 of 15 Old 03-21-2009, 05:23 PM Thread Starter
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Thanks mike, took some work but I think it was worth it

Simon
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post #4 of 15 Old 03-21-2009, 05:26 PM
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Wow - great write-up. Thanks for taking the time on this. Looking forward to the windshield install!

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post #5 of 15 Old 03-21-2009, 05:31 PM
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Nice work, wonder how that compares to Speedy's writeup on hooligantech.com .

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post #6 of 15 Old 03-21-2009, 05:32 PM
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Excellent write-up This thread will be referenced in the 919 Helpful Topics. I like the extra running lights, very cool...

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post #7 of 15 Old 03-21-2009, 05:46 PM
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Good job. Now you need some night shots.

"Towards the end of the vid, it looks like she may have had a bafflectomy." - MarylandMike
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post #8 of 15 Old 03-21-2009, 05:48 PM Thread Starter
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Thanks guys... will work on the windshield brackets tomorrow.. I'll keep you posted

Simon
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post #9 of 15 Old 03-21-2009, 05:49 PM Thread Starter
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...and I'll get some night shots as soon as the windshield is done HondaJim

Simon
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post #10 of 15 Old 03-22-2009, 02:02 AM
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Great writeup. When are you going to start selling premade wiring harnesses for this?

How does this setup compare to the stock as far as brightness at night? I've heard/read that the dual setup somehow isn't as bright as the stock.

2003 Honda 919 - flapper mod, Clear Alternatives Smoke Tailight w/ integral turn signals, Stebel Nautilus air horn, DIY fender eliminator, LED license plate bolts, LED front turn signals, no resistor or new flasher so I blink like crazy.
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post #11 of 15 Old 03-22-2009, 08:51 AM Thread Starter
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Thanks !, wont start production of premade harnesses it's pretty easy just a bit time consuming and I'm just starting to make decent welds lol ... I can help a fellow rider but won't start on a production level

As far as brightness goes.. I did a few short rides but no night rides yet it's still a bit too cold here for that... But considering the extra running lights and the fact that H4s came in stock, it should be bright enough

Simon
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post #12 of 15 Old 10-08-2012, 05:53 PM
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Relay types and wiring

Hi,

What type of relays are you using? Are the SPDT or DPDT? How many poles? Looks like 6? Can you detail the relay wiring?

I tried this with 2 4 pole 12v relays but could not get to work. My starter switch is fried.

Many thanks,

Sean

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post #13 of 15 Old 10-08-2012, 06:13 PM Thread Starter
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Hi Vshake,

I believe I used 5 prongs SPDT relays. Here's an article on automotive relays, it might help : FAQ: RELAYS; how they work and how to wire it up...

The important thing is NOT to use the ground on the headlight connector to avoid loading the original circuit which is designed to power only one headlight bulb.

I have been using this setup for 3 years now without a problem.

Cheers,

Simon
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post #14 of 15 Old 10-09-2012, 01:27 PM
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Relay Details

Great thanks! Just wondering if you can give me the specifics on the relays you used.

12 v Bosch type SPDT 5 pin 25 amp?

Do you have a make and part number by chance? Or link to types you used?

Many thanks!

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post #15 of 15 Old 10-13-2012, 08:03 AM Thread Starter
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I don't remember the make and model sorry :S

I wired it with the info on the mp3car forum :
FAQ: RELAYS; how they work and how to wire it up...

Simon
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