Mr. WheeliePete, THANK YOU so much for producing your video. I have a 2017 DRZ400SM and just installed a switch for my headlight successfully, Thanks to your video. You saved me a lot of time. Yours is the ONLY video on YT that is perfect advice for my bike. I also added some liquid rubber to the inside of the switch to help waterproof it. I had to splice the yellow wire w/ white stripe of course. I also jumped the clutch wire and removed the unused portion and plugged the hole. Thanks again!
I bought a 2005 s model awhile back. In that mess of a wiring cluster under the headlight, I found a toggle switch. The previous owner had done this mod, except it turns off ALL the lights. Headlight,turn signals, tail/brake light. I didn't really follow the wiring to see how he included the tail or turns, but he did.
Thanks for the video! But.... How can this work on a 2000-2004 model? There is no straight wire to the starter switch? Orange wire connects to Horn=>Engine Coolant Temp=>Speedometer=>front brake switch (not starter) Using the same diagram....
Does your headlight turn off momentarily when you hit the starter button? If it does, you should be able to put an inline switch on that wire up by the headlight Hi/Low switch. We did it to my buddy's 2003 KLX (which was just a DRZ branded by Kawasaki in that year). The wire does not run straight up to the starter switch, it goes through a few connectors along the way. It's got more than one job along the way for that year's bike. Link to the video part that shows the 2003 diagram: th-cam.com/video/xoxOSiK9i-s/w-d-xo.htmlsi=jmYgfnwoHZ3XEyQj&t=298
@@WheeliePete Finally.... The headlight does not turn off when starting the DRZ. Also...Keep in mind that the rectifier has to get rid of the extra amps (otherwise used by the headlight) through heat (via shunt to ground). Will get hot and could fail sooner than necessary.
Great video and easy to follow. I have a '07 DRZ400 and the charging system only shows a 12.2 -12.4 when running with the headlight on. It will go to 14. when I disconnect the headlight so after watching your video I am wondering if it the R R rather than the stator that I replaced with a Rick's a few K's ago. I thought if the stator is shot it would not show any signs of charging. Any thoughts?
I think you're probably on the right track, but I'd run through this article on Thumpertalk and do the troubleshooting sequence here: www.thumpertalk.com/forums/topic/541623-charging-system-diagnoses-plus-the-free-power-mod/
*Updating this comment tonight after looking at wiring diagrams* What year bike and is it US or another country production model? (There are some wiring differences between years as shown in the video. The video is specific to US 2006 model) If it's just switching the high/low, I think you must be tapped into the wrong wire. This mod essentially T's into the wire from the starter switch button to the headlight switch. The purpose of that wire is that it *should* kill the headlight momentarily when you start the bike to transfer all electrical load to the starter. If you put your wiring back together and you hit the starter button, does your headlight turn off momentarily when the starter button is depressed and the engine cranks? If it does then you have probably done the mod to the wrong wire. If the bike does not turn off the headlight when you hit the starter button, then there's probably some crossed up wiring in there. Has anyone (prior owners, etc.) been working on the electrical, adding lights, accessories, etc.? Sometimes new wiring getting added at various places can create alternate paths for circuits to be completed and cause some screwy things. Again, look at a wiring diagram for your specific bike to determine what color that wire should be that you want to create the new switch in. I had another viewer do this successfully to a 2017 DRZ400SM so I know this works on at least my 2006 and that viewer's 2017.
What Pro-Taper bar BEND you got and 'hand guards' - I want to ditch the stock bars and 'grips' with some no waffle ones. Can you list out the MODS and part numbers so I can match up?
Good video ! I will think about putting a switch for both front and rear light... do you have an idea ? I'm thinking of a connector with 2 wires. One go to the headlight, the other to the rear under the seat...
Yes, if the headlight is on everything still functions normally. In that part of the video where I show the headlight turning off during the starter button push, my interrupt switch was already wired in at that point. Putting in the switch does not have any effect on any other bike systems.
The WIRING is a like DISASTER behind the headlight - like such a mess still in the year 2021 goin to the LED headlight and rear tail and blinkers. Wish there was a way to 'clean this up' but sadly there is not.
It's really hard to diagnose an electrical problem over the internet. Is your headlight coming on when you turn the key on? Do you have any electrical signs of life when you turn it on? If you do have electrical, but no cranking, the usual suspects (after you rule out the battery) are the safety switches in the kickstand and the clutch. I've got videos on how to bypass both of those: Clutch switch: th-cam.com/video/rGp0tnu89cU/w-d-xo.html Kickstand switch: th-cam.com/video/tluPLT5ZEHE/w-d-xo.html I'm pretty sure video files would be too big to go through to my email, but you can always post one privately on TH-cam and send me the link to it via e-mail: wheeliepete@outlook.com
Mr. WheeliePete, THANK YOU so much for producing your video. I have a 2017 DRZ400SM and just installed a switch for my headlight successfully, Thanks to your video. You saved me a lot of time. Yours is the ONLY video on YT that is perfect advice for my bike. I also added some liquid rubber to the inside of the switch to help waterproof it. I had to splice the yellow wire w/ white stripe of course. I also jumped the clutch wire and removed the unused portion and plugged the hole. Thanks again!
I bought a 2005 s model awhile back. In that mess of a wiring cluster under the headlight, I found a toggle switch. The previous owner had done this mod, except it turns off ALL the lights. Headlight,turn signals, tail/brake light. I didn't really follow the wiring to see how he included the tail or turns, but he did.
That sounds like the "run from the cops" version of this mod...lol
Thanks for the video! But.... How can this work on a 2000-2004 model? There is no straight wire to the starter switch? Orange wire connects to Horn=>Engine Coolant Temp=>Speedometer=>front brake switch (not starter) Using the same diagram....
Does your headlight turn off momentarily when you hit the starter button? If it does, you should be able to put an inline switch on that wire up by the headlight Hi/Low switch. We did it to my buddy's 2003 KLX (which was just a DRZ branded by Kawasaki in that year). The wire does not run straight up to the starter switch, it goes through a few connectors along the way. It's got more than one job along the way for that year's bike. Link to the video part that shows the 2003 diagram: th-cam.com/video/xoxOSiK9i-s/w-d-xo.htmlsi=jmYgfnwoHZ3XEyQj&t=298
@@WheeliePete Thanks for the reply! At the moment my DRZ is dismantled, so I cannot check this (just got the bike). Will check this... 👍🏻
@@WheeliePete Finally.... The headlight does not turn off when starting the DRZ. Also...Keep in mind that the rectifier has to get rid of the extra amps (otherwise used by the headlight) through heat (via shunt to ground). Will get hot and could fail sooner than necessary.
Great video and easy to follow. I have a '07 DRZ400 and the charging system only shows a 12.2 -12.4 when running with the headlight on.
It will go to 14. when I disconnect the headlight so after watching your video I am wondering if it the R R rather than the stator that I replaced with a Rick's a few K's ago.
I thought if the stator is shot it would not show any signs of charging. Any thoughts?
I think you're probably on the right track, but I'd run through this article on Thumpertalk and do the troubleshooting sequence here: www.thumpertalk.com/forums/topic/541623-charging-system-diagnoses-plus-the-free-power-mod/
Followed this video and tried for myself, the switch just toggles high beams on/off for me and doesn't turn headlight off? any ideas?
*Updating this comment tonight after looking at wiring diagrams* What year bike and is it US or another country production model? (There are some wiring differences between years as shown in the video. The video is specific to US 2006 model) If it's just switching the high/low, I think you must be tapped into the wrong wire. This mod essentially T's into the wire from the starter switch button to the headlight switch. The purpose of that wire is that it *should* kill the headlight momentarily when you start the bike to transfer all electrical load to the starter. If you put your wiring back together and you hit the starter button, does your headlight turn off momentarily when the starter button is depressed and the engine cranks? If it does then you have probably done the mod to the wrong wire. If the bike does not turn off the headlight when you hit the starter button, then there's probably some crossed up wiring in there. Has anyone (prior owners, etc.) been working on the electrical, adding lights, accessories, etc.? Sometimes new wiring getting added at various places can create alternate paths for circuits to be completed and cause some screwy things. Again, look at a wiring diagram for your specific bike to determine what color that wire should be that you want to create the new switch in. I had another viewer do this successfully to a 2017 DRZ400SM so I know this works on at least my 2006 and that viewer's 2017.
Same here, with an european 2007 S bike :(
Great video, thank you for posting. I have a 2007 DRZ S. maybe the same harness, will check it out.
What Pro-Taper bar BEND you got and 'hand guards' - I want to ditch the stock bars and 'grips' with some no waffle ones. Can you list out the MODS and part numbers so I can match up?
The bars are Pro Taper SE KX High bend. The hand guards are Acerbis X-Factor.
Good video ! I will think about putting a switch for both front and rear light... do you have an idea ? I'm thinking of a connector with 2 wires. One go to the headlight, the other to the rear under the seat...
With the headlight on does the is still shut down upon start up to give the starter all the juice? Thanks.
Yes, if the headlight is on everything still functions normally. In that part of the video where I show the headlight turning off during the starter button push, my interrupt switch was already wired in at that point. Putting in the switch does not have any effect on any other bike systems.
The WIRING is a like DISASTER behind the headlight - like such a mess still in the year 2021 goin to the LED headlight and rear tail and blinkers. Wish there was a way to 'clean this up' but sadly there is not.
Yeah, their cable management is really, really, poor behind that headlight.
Can I please send you a video of my bike and can you give me any pointers, my bike not starting..... No noise or anything,
It's really hard to diagnose an electrical problem over the internet. Is your headlight coming on when you turn the key on? Do you have any electrical signs of life when you turn it on? If you do have electrical, but no cranking, the usual suspects (after you rule out the battery) are the safety switches in the kickstand and the clutch. I've got videos on how to bypass both of those: Clutch switch: th-cam.com/video/rGp0tnu89cU/w-d-xo.html Kickstand switch: th-cam.com/video/tluPLT5ZEHE/w-d-xo.html I'm pretty sure video files would be too big to go through to my email, but you can always post one privately on TH-cam and send me the link to it via e-mail: wheeliepete@outlook.com
Suzuki's sad excuse for cable management AKA a bunch of crap you pay for in one shot. lol
Running without a light is .... haha