Friday, May 31, 2013

Dual beam headlights for the Pulsar 220

This is a DIY project on the Pulsar 220 to fully use the dual head lamps. Pulsar 220F, Pulsar 220 DTS-i and the Pulsar 220 DTS-FI all have two headlamps. A separate low beam and a high beam. But only one can be turned On at a time as a stock. This project attempts to turn both of them On whenever the High beam is turned On.

Dazzling! Rubert's bike on the left and mine on the right.

As a disclaimer use this procedure at your own risk. Also doing this may void your bike's manufacturer's warranty. However this procedure worked well on my Pulsar 220 F and also on my brother's 220F. I have used this setup for 3000+ kilometres now and only issue i noticed is the battery low icon lights up after riding slow with dual beam for  quite some time(20 min or so). Switching to low beam dismissed the battery low indicator.

Be warned that this could deplete the battery if a prolonged you use of both beam together for a long time. However, you will see the battery warning indicator on the dashboard if ever the battery voltage goes low. And by the way, please avoid using high beam against oncoming traffic, it could blind them.

Here is the procedure:

The bike already has a low beam head lamp and a high beam headlamp. The light bulbs are not changed. All that is done as part of this procedure is to turn the low beam On along with the high beam whenever the light switch is at the high beam position. When the light switch is at the low beam position only the low beam will be turned On(as in stock).

You would need the following:
  • 12 volt solenoid relay (10A) - 1 no
  • Relay pin connectors - 4 nos
  • battery connectors  - 2 nos
  • wire - 18ga.
  • Fuse 10A - 1 nos
  • switch - 1 (to toggle between stock setup and dual lamp setup - optional)
  • two LED pilot(W5W) lamps - optional

Basically take a lead from the +ve of the high beam and use it to turn on the low beam using a Relay.
This relay acts as a switch and powers the low beam bulb whenever the high beam is turned on. See below wiring diagram, it might talk better :).

Wiring diagram. (Sorry I am no electrical engineer!)

Now whenever the high beam is turned on the headlamp total power consumption will be 55 (low beam) + 55(high beam) + 10 (2 pilot lamps) = 120 W.

If you notice in the first picture above, the bike on the left has the pilot lamps not glowing(disconnected). While the bike on the right has white LED pilot lamps. To save the 10Watt consumed by the stock pilot lamps, my brother disconnected the pilot lamps altogether. While I replaced the stock pilot bulbs with W5W LED bulbs. You may do one of those or something better!

If you had either replaced the pilot lamps with LED or altogether disconnected them, then your dual lamp setup will consume 55 +55 = 110 W.

With this dual beam setup, you get the illumination of the low beam and the high beam at the same time. Happy night riding.

Update - 15th August 2014:
I tested with a multimeter the voltage in and out of the battery when the both low and high beam is on. What I understood is that at 3000 rpm and above, the battery gets charged even when both the beams are on. So the Dual beam headlight setup seems safe to use at and above 3000 rpm.