81 KZ550 LTD Dim Headlights

I have a dual headlight setup on my 81 KZ550 LTD. Low-Beams are single headlamp, Hi-Beam lights up both headlamps. In Low, the single lamp is dim, switching to Hi-beams, and they both light up very slowly and even dimmer than the low-beams. I have installed a new battery, but do not know why they are not lighting up properly.

For reference, the bulbs are H4 12V 60/55

Here is the headlight setup I have on the bike: Dominator Headlight with twin 3.5" assemblies

There must be a bad connection somewhere. First guess would be the fuse holders. Second would be the light switch or ignition switch contacts. Then there is the 50 miles of wiring. If you have the auxiliary lighting unit, that can be a problem too. That is easy to bypass.

I use dual 55 watt all the time and they are brighter than sh*t. But I also rewired the whole bike with new wires and cleaned all of the switches and put in a blade type fuse, sealed from weather, and eliminated the aux lighting unit (when you have dual lights, you don't need the aux unit).

Time to re-wire the bike! Found several bad connections in the harness. A lot of wire nut connections and electrical tape. Any resources for making my own harness, or anyone have a good harness for the KZ550-C2?

You may have to use a relay to power the lights for better current. Use the standard lighting circuit to power the relay energizing coil. I'd recommend using at least 14 gauge wire from the relay to the lights. Auto parts stores carry 30 and 40 amp relays(this means the current ability, not how much it draws when energized).

Wire Termination Insulation & Sizes

Terminal Insulation Color Wire Sizes
RED

---

22-18 gauge wire
BLUE

---

16-14 gauge wire
YELLOW

---

12-10 gauge wire

The ring terminal holes comes in many sizes, from #4 up to 1/2" in most cases, it's a matter of finding the tightest fitting hole to fit the fastener for the termination.

American Wire Gauge(AWG) is backwards to what many people think; that is 22 gauge is many times smaller than 10 gauge even though the number is bigger.


Relay Types & Wiring Information
www.the12volt.com/
www.2carpros.com/how_to/how_do_i_check_a_relay.htm
www.mcmelectronics.com/product/26-1942

Electrical Connectors, Wire, And supplies
www.easternbeaver.com
www.delcity.net
www.vintageconnections.com
www.z1enterprises.com/catalog.aspx?pid=KPEL1
www.vehicle-wiring-products.eu
www.electricalconnection.com
www.electricalconnection.com/electrical-components/hitachi.htm
www.hvccycle.com/electrical-connectors.html


Electrical Wire Harness Tapes (The non sticky type used in many car & motorcycle harness(looms).
www.pcsconnectors.com/harness_tape.aspx
www.deadnutson.com/catalog/item/2965331/6122491.htm
www.tapebrothers.com
www.wiringharness.com
www.findtape.com/shop/product.aspx?id=32...&width=1436&height=0


If you need information about wire stripping, & crimping tools, just ask.....

Well I found (HARNESS,MAIN | KZ550-C2 | (26001-1175)), online for $175.00. Now, I just have to hurry up and wait for it to get here. The lighting issue is only one of many on this old bike. Wiring harness may also fix several other electrical problems.

Wire nuts on a motorcycle is never a good idea! Most are open, allowing moisture to get in, creating corrosion, and twisted together wires covered in black sticky tape is another potential problem.

When creating a new wire harness for lighting for my bike, I use heat shrinkable tubing, and the splices will be of one of two types; a crimp type that's shrunk or a solder type, both have very good protection for the electrical joint, excluding corrosion creating moisture.

For 2 60w headlights I would use relay(s) and a separate fuse. That way the current won't need to travel the long and winding road though all those connectors, switches, etc. High/low switch will energize relay which will enable power to go from battery - relay(s) - bulb(s). Even with that you will need to use the high beams very sparingly because your generator won't handle that load and charge the battery. Ed