Dual Headlight Conversion - ZX6R Forum
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post #1 of 22 Old 07-02-2007, 04:28 AM Thread Starter
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Dual Headlight Conversion

SOMEONE MOVE THIS TO THE HOW-TO SECTION as i cant post in there for some reason.........


this mod will work for ANY kawasaki that has one the low beam as the left light (except the 06/7 ZX10's) ........ it took me a while but i figured it out. here is a write up on how you go about it.
well, my missus said she was annoyed that Kawasaki in their infinite wisdom made the left light only for low beam. so whilst she is away in Europe (with her permission ) i decided since i am off work to fix the problem.

heres what you need for a start....

a 5 pin, 30A relay (if you dont use a switching relay, you WILL melt your plugs, wiring harness and be up s.hit creek)

2 x H4 socket plugs for headlights

2 H4 bulbs ( the one on the right is the stock h7, notice the difference in size. We are going to have to modify the H4 to fit into the stock headlight)

Tin snips

and finally some wire strippers, electrical tape, and needle nose pliars.


First remove the headlight
(if you need pics for how t do this, do not do this mod. It will be way above your mechanical ability)

next, remove the two circle covers on the back of the housing
pull the sockets off the headlights, remove the rubber circle in the center of the headlight and pull the wiring out throught the hole

now youll notice the h4 is too big to clamp into the housing, so take the tin snips and start cutting down the bracket on the bulb. Your going to have to cut off the outer lip, just keep trimming small amounts and checking to see when it fits. Yo have to remove the cone inside the housing on the low beam side. I reccomend baking it in the oven and removing the front glass to pull it out. Or you can use a heat gun or clow dryer to heat up the glue and pull it out. I just held it with a pair of needle nose pliars and started butting at it with the snips untill i wa able to bend it throught the hole but i did scratch the reflector housing a little. You can only see it when you look real close.


Wire in the H4 plugs with the ground, low beam and high beam wiring plan (once again refer to manula if you dont know this)

replace the covers

now follow the wiring diagram. Do not cut off the harness! you are going to connect the stock plug on the headlight harness into the stock plug on the bike. Cut off the headlight bulb harnesses and splice those into the relay wiring.

Make sure to cut off the rubber cover so you can re use it. You only want to cut the center so it is a single hole and slide it off the old wires.

Run the new wires through it

Tape all your connections

Put the headlights back in and enjoy!!

Headlights on and back together

Low Beam

High Beam
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post #2 of 22 Old 07-02-2007, 11:20 AM
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PM crashtd and send him a link to this thread and tell him to put it in the how to and he will put it in there for you
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post #3 of 22 Old 07-02-2007, 11:46 AM
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Wow! Nice one.

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post #4 of 22 Old 07-02-2007, 05:28 PM
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if i had a $buck$ for everytime someone told me i have a light out..

niice mod, great post

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post #5 of 22 Old 07-02-2007, 08:44 PM
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Once again... Tell them to get a bike then they would understand

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post #6 of 22 Old 07-02-2007, 11:42 PM
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great mod and even had it out with a testing station about having a light out had to take the manual down to prove to them when getting a roadworthy wankers

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post #7 of 22 Old 07-03-2007, 12:20 AM
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Great post, Joker! PM either Crash or Steve and they'll move it for ya

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Originally Posted by crashtd View Post
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post #8 of 22 Old 07-03-2007, 12:10 PM
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i bought my bike already with this mod, being a newbie i didnt even notice, opps lol
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post #9 of 22 Old 07-04-2007, 01:46 AM
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Thanks for sharing bro..

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post #10 of 22 Old 07-08-2007, 10:31 AM
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if i had a $buck$ for everytime someone told me i have a light out..

niice mod, great post

i'd be a millionaire
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post #11 of 22 Old 07-25-2007, 12:59 PM
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Just completed the mod (before I had even ridden my new '06 for the first time). Great instructions and diagrams. Love the way the bike looks now. Thanks for the info!
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post #12 of 22 Old 07-25-2007, 02:09 PM
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I really want to do this and angel eyes but haven't the time.


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post #13 of 22 Old 07-26-2007, 05:08 AM
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It took me a couple days (started one night, finished the next morning). I'd say 4 hours total. I went a little slower because I was looking at a couple other things in the front, and also I had to run to Home Depot to get those tin snips. The hardest part was getting the little cone out of the low beam side, but with a couple good pairs of needle nose pliers and a little persuasion, I was able to yank it out through the headlight hole. The instructions and wiring diagram were perfect though....now I just got to finish my license plate mount mod....
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post #14 of 22 Old 08-09-2007, 11:12 AM
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hello there

I am going to try this mod on the weekend, could you tell me if this relay is ok http://www.in-car-stuff.com/shop/relay-spco-pi-59.html I dont want to get the wrong one.

Thanks
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post #15 of 22 Old 08-09-2007, 11:16 AM
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Should be fine. When I got mine, the guys at the auto store said that the important thing is that the little numbers all match up with the ones on the diagram (which it looks like they do)...

Let us know how it goes...
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