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Discussion Starter · #1 ·
I have to say.... While the headlight posts I was just reading were funny as hell and I totally relate to all of it, here I am 3 days later removing the front fairing so that I can just get it done right, with room to work. Less F bombs should be needed, I hope....

Trying to figure out what someone else did with the wiring prior to you owning it is just as much of a pain in the ass. But..... I win!

Now, I had a CBR for about 6 years before getting my GSXR. I've had it for about a year now and the projector has never worked. It was re-wired and a ballast put in for the HID H4 Hi/Lo bulb. There was a bulb in the projector, but not hooked up. I have now ordered another ballast and ordered a HID bulb for it as well. What is the purpose of the projector bulb if the upper bulb controls the Lo/Hi and Passing?

I have some underglow's I've installed and am doing a blue'ish purple thing going on with the two lights and hav3e some additional LED's for my own "halo's".... Hence another reason the headlight assembly MUST come out. This chick likes the purple, wasn't sure if I'd get in trouble around here with that color headlight, but none of the men in black messed with me tonight so, I guess all is good! What can I say? Wheel's up boys, let's ride!

05 GSX R600..... sexy biatch!
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why not ditch the ballast and HID's for LED? they make pretty good setups for bikes these days.. at least 2 (lo) or 4 (hi/lo) Cree XHP50's per stick.. you want good silent fans.. and onboard circuitry ... I'd get a bike specific setup for best fitment and circuitry...
 

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You should listen to me. No, seriously, listen to
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As I read the wiring diagram, the lower projector is a H7 low beam and should always be on. The upper non-projector is a H4 hi/low that is switched by the left handlebar switches. Two bulbs should always be illuminated. It's just a matter of which one of the H4 filaments is on. I think that HID H4's can get complicated. Some have one "filament" and a movable shield to effect the hi-to-lo change. Others have two bulbs, a HID and a halogen. Presumably the HID is the hi. Since the HID gets its power from a ballast, there are two sets of leads on the two bulb version. You'll have to do some rewiring to accommodate that, though rewiring will always be needed with HIDs. That also means that there will be turn on time delays for the HID, i.e. they don't come on instantly like a halogen (though they've improved significantly from what they originally were). On the movable shield bi-xenons you'll need power to the HID that's always on and wiring to control the shield, which will take some fiddling around. I've been suspicious of LED conversions but in your case it may be be a better (simpler) solution.

P.S. My copy of the service manual isn't very high quality and I'm not sure of the wire colors to the H4 connector. As best I can tell they're B/Y to the high filament, B/W to the common ground, and B/Bl (black with blue stripe) to the low filament. Can you confirm that? I'm particulary interested in knowing if the B/Bl is correct.
 

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Dreaming of buttsecks for years...
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LO is always on. For HI, the B/W is common ground. B/Bl is the low power filament. B/Y is the high power. These are one or the other. Where things might get confusing is the wire color change between the main harness and the front sub-harness. Even the wire colors change between the handlebar pods and main harness. Hopefully the previous owner patched in all in the front.

Most of the good HID/LED installs I've seen use an additional switch to power on. That way it's only switched on at running voltage. On the 05, the start button kills the headlights. On the 04, they're hot whenever the key is on. I just wouldn't like powering up a ballast, then killing it or undervolting it for a couple seconds.
 

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Discussion Starter · #5 ·
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LO is always on. For HI, the B/W is common ground. B/Bl is the low power filament. B/Y is the high power. These are one or the other. Where things might get confusing is the wire color change between the main harness and the front sub-harness. Even the wire colors change between the handlebar pods and main harness. Hopefully the previous owner patched in all in the front.

Most of the good HID/LED installs I've seen use an additional switch to power on. That way it's only switched on at running voltage. On the 05, the start button kills the headlights. On the 04, they're hot whenever the key is on. I just wouldn't like powering up a ballast, then killing it or undervolting it for a couple seconds.
 

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Discussion Starter · #6 ·
I had an HID H4 bulb in there using the previous wiring set up. It was ok, but my OCD was driving me nuts. I went ahead and just ordered a completely new set up with ballasts, etc. I am much happier knowing what is what in there.

Has anyone ever taken apart the headlight assembly? It's 2 pieces, but sealed, obviously. I've read quite a few posts regarding how to do this but I need to clarify.... Is it the housing that comes apart after being heated up or is it the glass on the front? I don't believe mine is glass though? 05 GSX R600
 
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