550 ltd reserve lighting unit

I have a 1981 kz550 ltd. My headlight is not as bright as it should be. i have a new H4 Halogen bulb. 60w/55w. my highbeam switch works, and both filaments work. its just not as bright as my dads 1986 vn750. I feel like im over riding my headlight at 20mph! i was told to replace the reserve lighting unit. My Headlight warning light is on. where is the unit located on the bike? thanks.

On some of the bigger 4's, the reserve lighting unit has a small 6 pin connector that mates with one going to the main harness.

It's probably behind a left side cover below the seat with the words "Reserve lighting unit" hot stamped in the unit.

on the kz1000 it is under the battery box.bj

Thanks. I will check that out. It looks like under my bat. box, there is only my R/R. hmmm ill keep looking.

If your bike does not have the reserve unit, try taking apart the left handle bar switch pod and clean up the high-low electrical contacts and related connections inside the headlight housing.

With the headlight removed, check the voltages at the three prong connector. BLACK with YELLOW stripe is the ground, RED with BLACK stripe should be high beam, with RED with YELLOW stripe being low beam.

For electrical connectors and contacts on my bike. I've been using a very good spray made by Caig Labs called "De-oxit". www.deoxit.com is the website and it can be purchased at Radio Shack Stores in the U.S. and at most good electronic supply stores.

I don't use WD-40 as it will later on turn into a non conductor(As I found this out some years ago).

My Factory Service Manual shows it behind the side cover, rectangle, Black,2 bolts, 6-pin connector. Also has full testing and diag. No substitute for FSM, 99924-1018-03. Its a hard copy, so sorry can't email/ post .pdf

MFolks wrote:

If your bike does not have the reserve unit, try taking apart the left handle bar switch pod and clean up the high-low electrical contacts and related connections inside the headlight housing.

With the headlight removed, check the voltages at the three prong connector. BLACK with YELLOW stripe is the ground, RED with BLACK stripe should be high beam, with RED with YELLOW stripe being low beam.

For electrical connectors and contacts on my bike. I've been using a very good spray made by Caig Labs called "De-oxit". www.deoxit.com is the website and it can be purchased at Radio Shack Stores in the U.S. and at most good electronic supply stores.

I don't use WD-40 as it will later on turn into a non conductor(As I found this out some years ago).

Should all the voltage readings be 12v for the H and L?

Motor Head wrote:

My Factory Service Manual shows it behind the side cover, rectangle, Black,2 bolts, 6-pin connector. Also has full testing and diag. No substitute for FSM, 99924-1018-03. Its a hard copy, so sorry can't email/ post .pdf

What bike do you have?

550C-1, the manual has the 82 as well. Do you have a fuel gauge, then the manual shows a reserve lighting unit for the C-2 model.
Have you tried a clean ground for your Black/ Yellow wire from the head light connector?

Mine has the fuel light. Its a 1981 c-2. why would it not have a RLU if it has a headlight warning light? i cant find it.

Might help to find the connector with these 6 wire colors.

Good Fortune!

What does the reserve lighting thing do?