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Headlight Bulb Wiring Identification and Help

Notes: You must decide the best places to cut your bike's headlight wires. Do not cut close to the bulb. Most modern bikes have plugs on the wiring loom which plug onto the bulb housings. Some have one main plug that plugs onto the headlight housing.

See some of the photos below for examples of where and where not to cut and if you have any questions, please contact me. It would be helpful if you include digital photos of the wiring leading into your headlights.

Headlight Power Plugs


	BMW 1150GS



	Good place to cut, a couple of inches from this plug. This bike has two plugs, each slightly different, one for each bulb.



	The plug on the left goes into the base of this bulb housing cover. Do not cut wires like these.



		Photo of bulb and housing on the bike. The housing cover on the left attaches to this housing.


	BMW K12RS/LT R1150RT

	Headlight wiring loom plugs in with one plug on the left side in the photo to the right. Cut the wires a few inches back from the plug (not shown).

	An exception is the headlight's ground wires. The Non-H4 Kit now includes extra long ground wires so that you can directly attach to the headlight grounds on the these bikes. These bikes sometimes have grounding problems due to the fact that both bulb grounds go to a junction just below the headlight lens. The Kit's grounds can be directly attached one to each ground wire. It is worth it to go to the extra trouble to locate and join the Kit's grounds onto these bulb grounds. By doing this you will assure good grounding and therefore full power to the bulbs. I would suggest removing the ground junction and bringing the two ground wires out through a hole you drill near the main headlight plug in the left of this photo. Then join the Kit's grounds to them outside of the headlight housing. Use a grommet for the exit hole or silicone them up to provide some strain relief and help seal the headight housing after drilling a hole.


	Note: ignore the numbers and arrows in this image


	H3 bulb - never cut a wire like this!

Alternate Installation - BMW R1100S


Here a customer has installed the Non-H4 Kit directly into the headlight wires. This bike has an H1 and an H7 bulb. The biggest problem with this type of install is routing the wires into the headlight housing. Very likely some kind of slots had to be made here in the housing caps for the wires. I would suggest actually drilling holes on the housing edge or sides to bring the wires in, and then connect them as shown.









		Here below you can see the main headlight plug. It is much easier to install the Kit's bulb wires here, just a couple of inches from the plug.


The main thing you want to do is power the headlight bulbs from the Kit's relays instead of through all the bike's wiring and HI/LO switch. I would advise you to keep your bike's headlight housing and wires intact if possible, and install the Kit to the wires outside the housings near the main plug. Each Non-H4 bike has different headlight bulbs, housings, and wiring. Look at what you have carefully before deciding how to install this Kit. I hope this page has given you some ideas of the best way to do this.