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Discussion Starter #1
You guys have been very helpful with other questions so here's my latest.

Need some guidance on ordering the correct headlight relay kit for my 14 DL 1000A4 with factory fog lights. Fogs are on with low and off with high beams and are wired into the harness under the tank, not at the headlight. My low beam connector melted and I'd like to correct the situation before my new headlight assembly does the same- provided it isn't a huge PITA or cause other problems. $70 kit vs $170 headlight assembly makes sense; not to mention the peace of mind.

My low beam is an H4, high beam is H7 and fog lights are LED. Since Eastern Beaver makes H4 kits I assume that is all I need to/ or am able to deal with. I also assume that their dual kits are for older VStroms with dual headlights (as opposed to using the 2nd plug to power fogs). So if I get a kit for a single H4, plug it in at the bulb and connect to the battery am I done? Will Hi/low switch and fog lights work the same as before?

The fog lights are the only electrical accessory I have or want, so I don't need room to grow. Also, I'm not comfortable splicing wires so I'd prefer the plug in version provided the cap will still fit. Very wet in my part of WA. Any input on getting the wire into the headlight assembly would be appreciated as well.

Thanks,
Mike
 

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My V2 low beam is a H7 not H4.

The plug on my low beam also melted.

I purchased my bike used and with all service records it was shown the previous owner paid to have the LB globe replaced, I believed the female spade fittings were stretched when the new globe was fitted thus causing the heat that melted the plug.

I replaced the spade fittings myself and I have had no problems since except I have had another globe fail recently.

Did you have any work done to your headlight before it melted or was it all original ?
 
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You guys have been very helpful with other questions so here's my latest.

My low beam is an H4, high beam is H7 and fog lights are LED. Since Eastern Beaver makes H4 kits I assume that is all I need to/ or am able to deal with. I also assume that their dual kits are for older VStroms with dual headlights (as opposed to using the 2nd plug to power fogs). So if I get a kit for a single H4, plug it in at the bulb and connect to the battery am I done? Will Hi/low switch and fog lights work the same as before?
On the Vee2 low beam is an H7 and high beam is an H9.
 

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Eastern Beaver doesn't make a relay kit for the Vee2. Making your own isn't that hard. One site that can help is the top chart at How to Make a Headlight Wiring Relay Kit: 3 Steps

12ga wire works fine. Since the low beam plastic headlight socket seems to be a problem, get the ceramic type.

The diagram shows ground connections as


Don't use the frame for a ground. Wire the grounds together.
 

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I traded emails with Jim Davis (Eastern Beaver) when I got my new leftover V2 last December (Jim picked up an Africa Twin in Japan) and posted about it in another thread months ago. He said there just isn't any demand at all for the Headlight relay kits on the V2 like there is on the other models. He guessed that they had changed something to prevent the problems. I posted the wiring diagram on another thread and there are no relays added to the V2.

He was supposed to check with Suzuki to see why the V2's were not reporting the problems of other years/models. I have never heard back from him. He made it clear that by now if there was a problem - he would have been told about it and responded with thousands of V2s out there and a lot of mileage on them. I was going to build my own kit and never yet got around to it. It is easy to do.

Has anyone heard of any switch or other related failures on the V2 recently related to the lack of headlight relays?
 
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FORUM GODFATHER.....R.I.P. PAT
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The single headlights will draw half the power of the duals on the other models so there shouldn't be many contact and connector failures. Relays will make the lights brighter though.
 

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That probably explains it then. I really don't ride at night but have some small Motomondo LEDs on all of the time for increased visibility on their own EB circuit. It should be good to go for day time riding.
 

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Discussion Starter #8
Appreciate the responses guys.

Looks like I misidentified my bulbs. Oops. Should have checked.

Rolex- I did replace the bulb (several thousand miles before the meltdown) with the correct part from my dealership so it was stock but not untouched. No problems fitting when I made the switch though.

The fact that Eastern Beaver doesn't have a market for a relay on this model suggests that this problem is not that common. It does sound like the weak link is the connector at the low beam bulb. Since I'm just looking for durability I think I'll look into upgrading that wire and socket which is outside the headlight housing and should be easy for a novice like me.

Thanks for sharing your research and expertise.
 

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I have created numerous wiring harnesses myself (after getting a giant bag of assorted Japanese type connectors a few years ago on EBay) for several bikes and ATVs. It has saved me a lot of $$ with only a little time involved. I have never had a problem on one of my harnesses.
 

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Rolex- I did replace the bulb (several thousand miles before the meltdown) with the correct part from my dealership so it was stock but not untouched. No problems fitting when I made the switch though.
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My globe was also changed like for like.

The female spade fittings on my low beam were very very soft as the bike was used I don't know if they were soft from the factory or from the poor connection ?

I got rid of the plug and just used 2 good quality fittings in place of the soft OME ones.

I built my own relay kit for my Wee but I have not yet seen a need for one on my V2.

I think everybody with a V2 should have a look at their plug especially if you have changed globes and keep a eye on the volt meter for a higher than usual voltage before starting the motor, this will show a headlight fault before it gets dark and stuffs a ride.
 

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There are ceramic sockets available for those with melting plastics.
 

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Discussion Starter #12 (Edited)
The old headlight is on the shelf since it bothers me when things melt for no apparent reason. After looking, it will be easy to replace the plastic socket with a ceramic one and the splice will be inside the weatherproof housing which is a plus. A pair of ceramic H7 sockets are on the way so I can practice on the old one. I'm thinking in-line crimp type connectors but I'm open to suggestions if that seems like a bad idea.

Received and installed the ceramic socket today. Works fine- looking forward to putting on some miles and forgetting about it. Always get good info here. Thanks guys.
 
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