Twin Headlights on a Birgman 400

[Gerard C]

I would put money on that this has been asked before but has anyone converted the Burgman 400 to have both Dipped beam? If so how.

[phil y]

I'm busy looking at that at the moment Gerard I will let you know if I'm successful. So far the lights take different size bulbs. I had a k5 before my present bike and I'm almost sure they both lit up on that bike.

[Normsthename]

Have a look on BurgmanUsa there are lots of people who have done it

Andy

[Raven]

I did a conversion on a 400 I had it was quite easy to do. Here's a link to the post, sorry there are no pictures now I lost them but the instructions still may be useful If I can find the pics I'll post them for you.

http://www.maxi-muppets.co.uk/forum/vie ... 67#p185967

Raven

[Jolly Bodger]

I'm considering this mod using Philips Xtreme +130% bulbs.

I've read Ravens description, shame the pics have gone.

I've made a diagram of how I think the wiring goes but could anyone who has already done this mod confirm I've got it right!

JB

[Jolly Bodger]

Hmmm I thought I might have had a response from someone who's done it!

[Raven]

Hi

I no longer have my Burgman but from what I can remember this is what I did.

The parts required

Headlamp Connector
http://www.ebay.co.uk/itm/HEADLAMP-SPAR ... xyhXRTNIfR

Relay
http://www.ebay.co.uk/itm/30-Amp-12-Vol ... SwPcVV2Gsj

Fuse holder
http://www.ebay.co.uk/itm/BRAND-NEW-STA ... xy5rpSPDdY

Blade connector
http://www.halfords.com/workshop-tools/ ... amp-female

Ring Connector
http://www.halfords.com/workshop-tools/ ... lated-10mm

10 Amp blade fuse (Red in colour)
http://www.halfords.com/technology/car- ... ses-10-amp

suitable lengths & grades of different coloured wire.


Remove front panel work, see this vid on youtube


On the headlamp plug that has both the main and dip beam wiring (righthand one looking at front of scooter), locate the wire that powers the dip beam. Add a suitable length and grade of wire to this. Either cutting and adding or splicing one to the side. I soldered all my connections but this is up to you.

On the headlamp plug that only has the main beam (lefthand one looking at front of scooter). If you look at this plug there is a little flap on the rear that just unclips and can be opened quite easily.

With the plug kit you have purchased you only need one of the metal connectors. Solder a a suitable length & grade of wire on the metal connection and slot it into the empty slot on the original plug and close the flap on the back.

On the rear of the dip switch there is a white wire that is no longer used, something to do with the original wiring when you had the option to turn the headlamps on or off. Anyway locate this white wire and follow it back down the loom. Again splice a wire into this as this will be you main power supply.

Now the wiring.
Find a suitable location for the relay, from what I can remember I placed mine on or close to the road horn and be sure that it is placed the correct way up (terminals pointing down)

The white wire you have attached your own wire to, add the inline fuse holder and 10amp fuse to this and cut to a suitable length. Connect this to terminal 30 on the relay, this is your main power supply.

Using a length of wire attach a standard blade connector to one end and attach to terminal 86 on the relay. Cut to length and on the other end attach a ring connector and bolt it to the metal chassis/frame of the scooter this is the earth wire.

Now on the the plug that had the main & dip beam supply you attached a wire to the dip beam power supply. Cut to length and attach this wire to terminal 85 on the relay. This is your relay switching supply wire.

Now the new wire & connector you have added to the other headlamp plug again cut to a suitable length and attach this to terminal 87 on the relay this is the power supply for the dip beam on the other lamp.

Tidy everything making sure there are no loose wires or connections. Insulate any bare connections and check that no wires are rubbing that could in time rub through a short to earth. If you have a volt meter, test the whole circuit to see if everything is working as it should. If all is ok plug two bulbs into the headlamp plugs and test that all works ok. If you are happy that everything is working as it should then put everything back together. If all is well you should now have two lamps when on dip beam.

As I said above it's been a couple of years since I did this but as far as I can remember this is what I did. The only thing different is using the white wire as the main power supply. Originally I used the dip beam supply that was on the headlamp but found out after that this wire was not man enough to supply power to two bulbs and could become overheated.

Hope this helps and of course you do this at your own risk as again it has been a while since I did this.

Raven

[Jolly Bodger]

Thanks Raven