Automatic headlight control


Ever forget to switch-on the headlight ? No more a problem with this mod. It works when the bike moves, as soon as a gear is engaged.

This mod is primarily intended for TDM900 2002, TDM850 - TRX850 - XTZ750, and actually all machines with a manual headlight switch. It will fit easily on TDM900 2003 + (with automatic headlight control), but is it less useful then...

How does it work ?

The circuit uses a relay to control the headlight. It is activated when a gear is engaged, and reset itself only when the main switch is switched off.

The circuit controls the headlight only, not the pilot lights. The original light switch may still be used as usual - actually it will be used only to switch on the pilot lights.
Anyway check your local daylight riding regulation concerning the headlight / pilot light.

Circuit description

(image)Composants :
• T1 : SCR (thyristor) C106A or equivalent.
• OPT : opto-coupler LTV816 / 4N25 or equivalent.
• D1 : diode, 1N4001.
• LED : any standard type.
• C1 : capacitor, 100nF.
• C3 : capacitor, 100µF.
• R1-R4 : resistors 5% 1/4W.
• K : 12V/12A power relay.


All these components are very common and available from all electronic components retailers.
Use a hot glue gun to secure the components & the wiring.

Casing

My casing comes from a salvaged car indicator relay, the relay inside was ok for the job. I had to remove the other components, modify the PCB and then add new components. The original connectors are kept and a small PC connector is added to connect the LED.

The casing is located right next to the ECU, hooked to an existing support where the 2003+ headlight relay is located.

Connectors

• HeadLight : headlight live wire, to the main light switch connector (located under the airbox).
• VCC HL : +12V power from the main light switch connector.
• VCC : +12V from the main light switch connector.
• RUN : chassis.
• Neutral : neutral switch from the blue connector located behind the black left-hand side panel.

Use wires with adapted gauge (at least 10A current) for HeadLight and VCC HL. All other wires are ok with smaller gauge, just avoid too thin or rigid wires - vibrations will destroy them !

Pictures

(image)
Salvaged part : an old indicator relay.
(image)
Inside : the relay is kept, other components are added.
(image)
The casing is located next to the ECU (2002).

TDM900 2003+

Models from 2003 on (2002 on OCE) have an automatic headlight relay. The relay is switched on by the ECU as soon as the engine is running.

Adapting the circuit above is relatively simple since the relay is already present (near the ECU).
The headlight will then switch only when you start riding, not when the engine is running.

(image)
Original headlight relay wiring
(image)
Modified headlight relay wiring : modified wiring shown in red color.
(image)
Modified headlight circuit diagram.

• The circuit is inserted between the oem headlight relay and the ECU command.
• The relay is connected to the circuit at RELAY.
• The ECU command is connected to the circuit at RUN.
• +12V is connected to the circuit at VCC.

TDM900 - 2002

The TDM900 2002 has no ECU controlled headlight relay, although this feature is available on the ECU but left unused (2002 EUR models only, 2002 OCE models have the relay).

It is easy to add this feature on any 2002 EUR model : just mod the ECU connector, then add a relay + diode and some wiring like on any 2003+ models.

Since the ECU connector pins are quite special, the best is to reuse the pin from the airbox solenoid (that means two mods at the same time).
• remove the ECU connector and unlock pins by pushing the white inserts.
• remove the Brown / Black wire / pin (red, see diagram below).
• relocate the pin on the blank green pin location (swap the cap seal).
• replace the airbox solenoid (under the air filter box) with a relay + diode and make all connections required for the headlight (see wiring diagram 2003+).
• or simply replace the airbox solenoid with the above circuit.

(image)

Sign-in×

Please enter your account name & password

Username
Password

Lost account detail ?

OkCancel
Lost account detail×

Enter your e-mail to receive your account detail

E-mail

OkCancel
Sign-up×

Why sign-up ?

  • It's free but you can make a donation.
  • You gain access to fonctionalities otherwise not available.
  • It will boost your sex-appeal and allow you to time-travel.

How to sign-up ?

UsernameRequired - 3 to 20 letters or digits
PasswordRequired - 6 to 20 letters or digits
E-mailRequired - enter a valid E-mail address
Country

OkCancel
My account×
PasswordE-mailDelete

Modify my password

Current password

New password
Confirm new password

Modify my E-mail

Current E-mail

New E-mail
Confirm new E-mail

Delete my account

Current password

OkCancel
Add commentEdit / delete message×
  • Your comments, feedback and suggestions are welcome !
  • Please use forums for any questions requiring a quick answer.
  • Your questions should relate to the TDM / XTZ / TRX only.
  • No links, ads, sales, doc requests. Thanx.
  • Edit your message then click the 'Ok' button.
  • Click the 'Delete' button to remove the message.
  • An empty message will be deleted.
NameRequired - 3 to 20 letters or digits
CountryOptional
E-mailOptional - will be encrypted
Message

OkCancelDelete

OkCancel
Terms of Service and Privacy Policy×

Collection & use of your personal information

When registering to the site, you will be asked personnal informations such as your e-mail address, your country of origin, etc. This site will not provide or sell your personal information to a third party without your consent.

The site may collect information about your visit in order to operate and improve the site and the service it delivers. This includes the pages you view, the links you click and other actions taken in connection with the site. It also collect certain standard information that your browser sends to every website you visit, such as your IP address, browser type and language, access times and referring Web site addresses. Theses data is collected only for statistical usage and will not be used for any other purpose. This data is periodicaly erased (max 3 months).

Use of cookies

This site uses cookies to memorize your display language option and your session data. No personnal information is stored into the cookies. If your browser does not accept cookies, you will not be able to change language or open session.

Use of e-mail address

This site will not sell, lease or rent the e-mail you provide while registering or posting messages. E-mail addresses will not be used for any purpose other than sending you service e-mails : registering confirmation, updating your data or requiring a new password.

Rules

This site does not allow any messages containing :

  • Spam : repeated (commercial) messages.
  • Referral Programmes or Pyramid Schemes (links to websites through which you have a personal gain).
  • Rude and disrespectful behaviour, whether it is to members of this site or the staff of this site.
  • Language that is obscene, vulgar, sexually orientated, hateful, threatening or violate any laws.
  • Offerings of products (tangible or intangible) and services that you do not have legal disposition over.

This site reserves the right to edit or delete reactions and to ban any user violating the rules without notice. Freedom of speech is a right, however this does not mean we are obliged to publish your opinion.

This policy is subject to change without prior notice.


Ok

Ok

Ok

Ok
Send SMS×
NameRequired - 3 to 20 letters or digits
Message

OkCancel