Headlight Relay: For 100/80w Bulb

[BaZa ®]

I have been running a 100/80w H4 bulb for a couple of years now and yes I did have a meltdown with the connector to the bulb.

Thanks to the warning I saw in THIS thread by Penfold.

Dave (ukid76) and I got talking down the Ace last week and he went and made up two relays for our bikes all available from Maplins or any good electrical accessory shop.

There is a 30amp fuse fitted and plenty of room in the nacelle for the relays.

So now my 100/80w bulb is drawing it's current along a piece of wire that is designed for it.

Thanks Dave & Penfold.

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[BaZa ®]

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[Ukkid76]

Something Baza forgot to mention,

It’s important to replace the earth wire to the bulb as well as the power supply, I used two relays one for main and one for dip beam, I ran an earth and power wire direct from the bikes battery, all terminals are crimped and then soldered where ever possible for added durability, I purchased a replacement three pin headlamp bulb connector from a motor factor, that allowed me to completely upgrade the wiring to the 100w diamond blue bulb, one more thing, you should never rely on just crimped connectors especially on more heavy duty applications.

All wires and connections have been covered in a double helping of heat shrink to give it that more professional look,

Just one thing you must be aware of, by upgrading to a 100w bulb and renewing the wiring, (as you have to or a fire is imminent), you are potentially creating more things that can go wrong like two relays extra wiring 12 more connections soldered or not can still give problems in later life!!

However if anyone wants a wiring kit to fit themselves send me a PM, I’ll knock one up for you, will have to cover costs though!!

Dave Cox

[1200shovel]

And don't forget that anything over 55watts is illegal!! and for off road use only, like my numberplate.

[Ukkid76]

Originally Posted by 1200shovel

And don't forget that anything over 55watts is illegal!! and for off road use only, like my numberplate.

That's news to me I thought most new cars (the more expensive ones) had 100/80w headlamp bulbs!!!!!

Well I’ll be buggered!!!!!

you learn something new every day,

God knows what would happen if I were stopped by the fuz they would have a field day, what with a slightly undersize number plate exhausts with “not for road use” stamped on them no numberplate light no rear reflector Screamin eagle everything a DOT helmet and now an oversize headlamp bulb shit just how far will they throw the key


And I suppose if you take all the above into consideration that would make my MOT void which would in turn void my insurance and I thought I was an law abiding citizen, mind you who gives a shit I was fined £60.00 the other day for being forgetful, I forgot to pay my congestion charge

Dave cox

[nick_dj]

One Question you have not mentioned is how much better is the light?
Nick
The bike looks great, hope to see it at a rally

[BaZa ®]

Originally Posted by nick_dj

One Question you have not mentioned is how much better is the light?
Nick
The bike looks great, hope to see it at a rally

No brighter as I have the same bulb as before the relays and new wiring...Just a lot safer.

I'll be at a few rallies see yer around.

[Ukkid76]

Originally Posted by BaZa ®

No brighter as I have the same bulb as before the relays and new wiring...Just a lot safer.

A 100w bulb is definitely brighter than a standard bulb, but be careful because some headlamp units stipulate a max of 60w bulbs so changing the wiring may not be enough.


I'll be at a few rallies see yer around.

Baza I think he ment MY BIKE not your flee ridden thing

Dave Cox

[BaZa ®]

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