Blue wire bypass - headlight relay mod - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums > Technical Forum > Electrical > Blue wire bypass - headlight relay mod
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post #1 of 33 (permalink) Old 03-23-2014, 05:32 PM Thread Starter
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Blue wire bypass - headlight relay mod
This guide bypasses the headlight relay, lighting your headlight when you turn the key, instead of when the engine turns.

Don't ask me about the pros/cons of this; I'm sure it will be discussed.

Video detailing the procedure at https://www.youtube.com/watch?v=C1_1MTfiJb8

On the left side of the bike remove the side cover. Unscrew the bottom screw and pull the side cover off. If you are sitting on the side of the bike, facing the side cover, pull directly toward you.

http://i16.photobucket.com/albums/b5...323_061053.jpg
You will see a Palm sized black box with two connectors coming out the right side of the box. One is a smaller ten pin, one is an 8 pin.

http://i16.photobucket.com/albums/b5...323_061153.jpg

Don't make the mistake I made - don't touch the ten pin connector. I pulled the blue wire from the 10 pin and moved it to the 8 pin. This is WRONG.

Pull out the 8 pin connector.

http://i16.photobucket.com/albums/b5...323_061246.jpg

There is a blue wire. Pull the blue wire out of its spot (or push it from the front of the connector to reduce stress on the wires) and move it to the empty spot on the same connector.

http://i16.photobucket.com/albums/b5...323_061333.jpg
http://i16.photobucket.com/albums/b5...323_061559.jpg

If the spade connector pushes out as you push the connector in, just connect the plug, then push the spade connector into the empty spot to secure it.

Operation complete.
Last edited by crowley1027; 03-23-2014 at 07:06 PM.
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post #2 of 33 (permalink) Old 03-26-2014, 08:59 AM Thread Starter
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Sticky worthy?
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post #3 of 33 (permalink) Old 03-26-2014, 09:56 AM
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Thanks, much appreciated! A reasonably easy mod to do, but having pictures to look at definitely works better for me to understand what is to be done.
1996 VN 750
2007 Vulcan Mean Streak SE

When I was younger I was afraid I'd die riding. Now that I'm old and falling apart, I'm afraid I won't.
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post #4 of 33 (permalink) Old 03-26-2014, 12:59 PM
..have a vulcan good day!
 
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Well done - a great detailed write up ...with pics !

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!
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post #5 of 33 (permalink) Old 03-26-2014, 05:50 PM Thread Starter
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Glad it's appreciated
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post #6 of 33 (permalink) Old 09-27-2015, 07:21 PM
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Quote:
Originally Posted by crowley1027 View Post
Sticky worthy?
Done
Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
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July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #7 of 33 (permalink) Old 01-30-2016, 02:22 PM
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My headlight's bright light didn't work so I bought a new bulb. This didn't fix the problem.
I figured I had nothing to lose by switching this blue wire to bypass the headlight relay.
This fixed it. Bright light now works.

Thanks
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post #8 of 33 (permalink) Old 01-30-2016, 05:07 PM Thread Starter
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Glad it's still of use
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post #9 of 33 (permalink) Old 03-29-2016, 04:53 PM
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Based on the diagram on page 15-36 in the manual, this bypasses the headlight fuse as well. May want to seriously consider adding an in-line fuse to protect things.
1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.
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post #10 of 33 (permalink) Old 03-31-2016, 10:44 AM
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Based on the diagram on page 15-36 in the manual, this bypasses the headlight fuse as well. May want to seriously consider adding an in-line fuse to protect things.
Actually if you see the schematic on page 15-50 for the junction box 8P connector, all you are doing here is removing the output from pin 8 and moving to pin 7. All that does is to take the headlight relay out of the circuit, the 10A headlight fuse (24 on the diagram) is still in the path. And you can verify that it is, by pulling the fuse after doing the repair, and seeing that the headlight will stop working.

This is a great mod, and can't beat the price !
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