Dipped Beam Wiring Mod (Old & New Switch Types)

[amb67]

Aprilia RSV Light Switch Dipped Beam Wiring Modification

Firstly, this is mainly for RSV's that have had the headlamp dipped beam converted to HID but can be used on all RSV's.

What will this modification do?

It will allow the dipped beam to remain on when you activate the main beam switch. This will give you much better night vision due to having all three lamps illuminated at the same time.

Currently, when you hit the main beam button your dipped beam will go out. Try it and see, if it doesn't then you don't need to do this modification.

Apparently we have two types of light switches fitted to the RSV, we will call them old and new for this exercise. Please refer to the correct part of this 'How to' for your switch type.

Old-style Switch
For the older switch type, un-solder the black wire and re-solder to the centre connection point.

Standard wiring
http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/OldSwitchUnmodded.jpg

Modified wiring
http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/OldSwitchModified.jpg

New-style Switch

The newer switch looks like this when you get it apart:

http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/NewSwitchUnmodded.jpg

Remove the plastic cover that hides the dip switch then pop the dip switch out.

Either unsolder the black wire (A) and re-solder it to the white wire (B) or solder a short piece of wire between A and B (I think this is easiest). Make sure you use a similar gauge wire to the other wires in the switch.

See picture below

http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/NewSwitchModified.jpg

Reassemble the switch and your conversion is complete.

This is a how to guide and all modifications are done so at the owners’ risk.

[danf1234]

Is this applicable to the 04 and onwards model bikes?

[amb67]

Is this applicable to the 04 and onwards model bikes?

I'm unsure that the 04 models have an issue with the dipped beam going out as us pre 04 model owners do.

The old and new style switches refer to two different types fitted to the 98 - 2003 models.

Perhaps someone with a bit of electrical savvy could have a look at the lighting set up on the 04 models and let us now if it is applicable.

[supertedlover]

amb mate is this in the how to forum yet? if not get onto the mods
your write ups a sh1t hot mate but your creating me more jobs :biggrin

[amb67]

Sorry STL for all the work I'm creating for you. LOL

PM'd CrashTD so should get moved soon.

Working on a HID how to at the moment, is taking a little longer than anticipated.

PS. I'm also trying to change my dash illumination colour to blue too, will let you know how I get on.

[Garvey2003]

Damn, looks like im getting the soldering iron out this weekend :) top how to. simple, easy to follow and very useful!

[Smiffy]

Mr ABM67, I have just performed the switch re-wire after seeing your above post, I have a 2002 model Mille on an 03 plate, I had the newer type switch and all is working well. Now when I'm riding down the road with my new HID kit and I flick on my full beam I will be able to see even more. .......many thanks for a great mod.....smiffy

[rsvrrr]

I've got the old style switch. I'll get in the garage and get on that tomorrow. Very clear and straightforward.

What's the HID conversion, cost hassle etc? My bike has the standard set up.

[Shake n Bake]

Does anyone know why Aprilia didn't design the headlamps to keep the dip lights on when you turn on the full beam? I am thinking about doing this mod but in the back of my mind I'm thinking that those great Italian electrical engineers at Aprilia might have had the same idea but backed off because of a potential overload or burn out situation.

[Mick Oliver]

Thanks well descrbed will make the mod this weekend:thumbup

[amb67]

Does anyone know why Aprilia didn't design the headlamps to keep the dip lights on when you turn on the full beam? I am thinking about doing this mod but in the back of my mind I'm thinking that those great Italian electrical engineers at Aprilia might have had the same idea but backed off because of a potential overload or burn out situation.

You must be joking!! LOL

Great Italian electrical engineers do not exist in the Aprilia factory, for sure.

I've been running mine modified for months and have never had an issue, have you read any posts of melted wiring looms etc.... after doing this mod?

No neither have I.

I am running a HID dipped beam so the actual current drain is less than that of a 60/55 H4 bulb.

If you've not converted to HID yet then I'd recommend it as one of your first mods. Helps be seen and to see in poor light conditions.

[Smiffy]

You must be joking!! LOL

Great Italian electrical engineers do not exist in the Aprilia factory, for sure.

I've been running mine modified for months and have never had an issue, have you read any posts of melted wiring looms etc.... after doing this mod?

No neither have I.

I am running a HID dipped beam so the actual current drain is less than that of a 60/55 H4 bulb.

If you've not converted to HID yet then I'd recommend it as one of your first mods. Helps be seen and to see in poor light conditions.

Im with Alan, this is a brilliant mod, but to be fair after adding a HID kit i hardly use the full beam, but when the weather is a little better and we start doing the Friday night ride outs until around 2am in the morning im sure it will come into its own!

[Shake n Bake]

You must be joking!! LOL

Great Italian electrical engineers do not exist in the Aprilia factory, for sure.

I've been running mine modified for months and have never had an issue, have you read any posts of melted wiring looms etc.... after doing this mod?

No neither have I.

I am running a HID dipped beam so the actual current drain is less than that of a 60/55 H4 bulb.

If you've not converted to HID yet then I'd recommend it as one of your first mods. Helps be seen and to see in poor light conditions.
I agree, I haven't heard of anyone having melted wires either but I bet I would be the first!
I don't think I'll install HID lights this year partly due to the cost and partly because I'm more of a day rider. But as the bike is currently in a state of undress I think I try the light mod.

Keep your eyes peeled for a pissed off RSV rider pushing his bike home!

[TTrouble]

Cost? I paid £30 for my HID kit!!!

[Shake n Bake]

Cost? I paid £30 for my HID kit!!!
That seems cheap, where did you get that from?

[AREESSMILL]

Best mod you can do.

and for 30 quid its worth it.

[Mick Oliver]

Where can you get one of these HID kits from:dunno

[amb67]

Where can you get one of these HID kits from:dunno

Try this guy Mick Click Me (http://cgi.ebay.com/ebaymotors/Motorcycle-H7-Xenon-HID-Conversion-Kit-6000K-SlimBallas_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1301Q7c66Q3a2Q7c65Q3a12Q7c39Q3a1Q7c240Q3a1318QQ_trksidZp3911Q2ec0Q2em14QQhashZitem300287564253QQitemZ300287564253QQptZMotorcyclesQ5fPartsQ5fAccessories).

I have had a few kits of him now for my bikes and a few mates cars too and they are excellent bits of kit.

They can take about 2 weeks to arrive but worth the wait IMO.

[Mick Oliver]

Thanks bud got the link will give it a try:thumbup

[petrolpete]

Aprilia RSV Light Switch Dipped Beam Wiring Modification

Firstly, this is mainly for RSV's that have had the headlamp dipped beam converted to HID but can be used on all RSV's.

What will this modification do?

It will allow the dipped beam to remain on when you activate the main beam switch. This will give you much better night vision due to having all three lamps illuminated at the same time.

Currently, when you hit the main beam button your dipped beam will go out. Try it and see, if it doesn't then you don't need to do this modification.

Apparently we have two types of light switches fitted to the RSV, we will call them old and new for this exercise. Please refer to the correct part of this 'How to' for your switch type.

Old-style Switch
For the older switch type, un-solder the black wire and re-solder to the centre connection point.

Standard wiring
http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/OldSwitchUnmodded.jpg

Modified wiring
http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/OldSwitchModified.jpg

New-style Switch

The newer switch looks like this when you get it apart:

http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/NewSwitchUnmodded.jpg

Remove the plastic cover that hides the dip switch then pop the dip switch out.

Either unsolder the black wire (A) and re-solder it to the white wire (B) or solder a short piece of wire between A and B (I think this is easiest). Make sure you use a similar gauge wire to the other wires in the switch.

See picture below

http://i167.photobucket.com/albums/u144/amb67/RSV%20Light%20Switch%20Mod/NewSwitchModified.jpg

Reassemble the switch and your conversion is complete.

This is a how to guide and all modifications are done so at the owners’ risk.

Well that is a way of doing it.
I am not over keen on messing around with the loom.
I have myself achieved the same by soldering a diode from the high beam relay to the low beam relay (cathode side of the diode on the low beam + coil side of the relay and Anode side on the + coil side of the High Beam relay).
The benfit of this is that it is reversible in minutes and also means you don't have to mess around with the loom. (I have got some pictures somewhere and will try and post them up).
Oh and I have also since fitted a HID kit, if you fit a HID kit this mod is essential as the HID light unit takes time to fire up and this could be potentially dangerous as when the high beam is switched off it will take a few seconds for the low beam to come to full brightness.
Pete :thumbup

[B o B]

Well that is a way of doing it.
I am not over keen on messing around with the loom.
I have myself achieved the same by soldering a diode from the high beam relay to the low beam relay (cathode side of the diode on the low beam + coil side of the relay and Anode side on the + coil side of the High Beam relay).
The benfit of this is that it is reversible in minutes and also means you don't have to mess around with the loom. (I have got some pictures somewhere and will try and post them up).
Oh and I have also since fitted a HID kit, if you fit a HID kit this mod is essential as the HID light unit takes time to fire up and this could be potentially dangerous as when the high beam is switched off it will take a few seconds for the low beam to come to full brightness.
Pete :thumbup

Hi Pete,

Now that sounds like my kind of mod. :thumbup I have an HID dip light fitted and have the same reservations as you when switching from main to dip. Please post the piccies and diode details.

[petrolpete]

Right,
I have done this modification to my bike a while ago and have done it by adding a diode.
This achieves the following result:
Low beam control on: low beam light on
High beam control on: both low and high beam are actuated.
This method has the following advantages:

It is easily reversible
It is virtually impossible to get wrong
It costs pennies
It should work on any bike

Ok firstly the theory:
Each one of the headlight control circuits makes use of a relay so that the current going to the lamp does not have to go through the control switch.
The low and high beams are controlled in the same fashion.
The following diagram shows the wiring principle.
http://i153.photobucket.com/albums/s212/petroleumpete/Bike/a8a3e1c0.jpg
The modification consists of using a diode, in simple terms a diode is a bit like a one way valve for electrical currents.
A diode is shown in the following diagram:
http://i153.photobucket.com/albums/s212/petroleumpete/Bike/198c0a3f.jpg
The diode will only allow the current and therefore allow the voltage to be the same in one direction: so if we put 12V on the Anode end (the end furthest away from the white stripe) the other end will be at 12V (minus a 0.6 V or so don't ask as it gets technical but it will put through enough to energise a relay.
Also in reverse if we put 12V on the Cathode (the end the closest to the white strip) the voltage on the other side will not be 12 but 0V.
So the diode is insterted between the two control circuits in the following fashion:
http://i153.photobucket.com/albums/s212/petroleumpete/Bike/23c4b8b9.jpg
This can be applied to all bikes early and late milles alike oh and may even apply to the new non milles RSVR's :nana (as long as the control circuit is the same aas shown in the first picture).
Ok now onto the doing it:
You will need:
A soldering iron (maplins or any hardware store have them for not much money or borrow one)
Some solder (usually comes with soldering iron)
A diode: now as this is not going to conduct much current any standard low power diode such as a 1N4001 will do perfectly. These are available from any component shop, any Tv repair place will have some Maplin also stock them http://www.maplin.co.uk/Module.aspx?ModuleNo=19079 and they cost pennies. :thumbup
I did it on my 02 Shape Mille and removed the relays from the base and soldered the diode as shown in this photo:
http://i153.photobucket.com/albums/s212/petroleumpete/IMG_1066.jpg
Note the side on which the white stripe is on the diode (if you get this the wrong way round it will not work).
I found it easier to remove the relay holder from the left side of the front subframe.
I then reseated the relays.
http://i153.photobucket.com/albums/s212/petroleumpete/RelaysInholder.jpg
I made sure the diode was tucked in under the lid of the relay holder (you could put the relays in some sheathing to ensure it does not short out with anything.
http://i153.photobucket.com/albums/s212/petroleumpete/IMG_1069.jpg
And it looks like this with low beam:
http://i153.photobucket.com/albums/s212/petroleumpete/IMG_1072.jpg
And Like this with high beam:
http://i153.photobucket.com/albums/s212/petroleumpete/IMG_1073.jpg
And the last great thing about this mod is that it is reversible in seconds.
I have not had any issues with the MOT with this fitted.
Have fun.
Pete :doug

[Sprocker]

Excellent write up pete :thumbup

Now where's my soldering iron again :biggrin i'm getting fed up removing panels every other week to do wiring mods :roll has anyone else got anymore whilst i'm at it before i rebuild it all :laugh

[Mick Oliver]

Excellent report well explained and easier to do than the switch:thumbup:biggrin

[B o B]

Top man Pete. I'm on my way to Maplins today.
Thank you :thumbup

[Sprocker]

Just about to order one from maplins from the link...14p for the diode and £2.60 postage the robbing :jack

I'll wait till i next go to Makro in Leeds, there's a Maplins on the way, not that i'm a tight arse or owt :biggrin

[B o B]

Yep, 14p and 1.50 for heat shrink wrap (1mm x1.5M) which is not vital but I'm going to buy it anyway. Oh yes, there is a Maplins less that half a mile away.:doug

[Sprocker]

Yep, 14p and 1.50 for heat shrink wrap (1mm x1.5M) which is not vital but I'm going to buy it anyway. Oh yes, there is a Maplins less that half a mile away.:doug

Bit of a cheeky question BoB, but if i sent you a stamped address envelope with the money in would you get me one whilst your there matey :biggrin


Hey ...you dont ask you dont get :biggrin

[Black Sabbath]

Bit of a cheeky question BoB, but if i sent you a stamped address envelope with the money in would you get me one whilst your there matey :biggrin


Hey ...you dont ask you dont get :biggrin

Tight northern bugger:biggrin

ehem Sssshhh I will do the same bro so order 3 but its a secret ok!:thumbup

[AREESSMILL]

Great Stuff Pete

I would adding HID xenons though as it makes a world of difference for about 30 quid.

[petrolpete]

Just re-read my original post and I said get some shrink to put the relays in.
I'm pleased to see you understood it as put some shrink on the diode so that it can't short out with anything.
I would need to have a closer look at the wiring diagrams for the 04, but am pretty sure it will work on them.
Have fun.
Pete (thinking the best ideas are always the easiest)

[Mick Oliver]

Been to maplins 14p soldered in didn't take long:thumbup

Cheers for the post :thumbup:thumbup:biggrin

Job now done:thumbup

[B o B]

Sprocker & Black Sabbath - I'm on my way to Maplins this morning. I'll get several diodes so let me know your addresses and I'll post one to you.

[Sprocker]

Sprocker & Black Sabbath - I'm on my way to Maplins this morning. I'll get several diodes so let me know your addresses and I'll post one to you.

pm sent BoB :thumbup top geezer :thumbup

[B o B]

pm sent BoB :thumbup top geezer :thumbup

Got it. Reply sent and it will be in the post by the end of the day.

[Sprocker]

A true gentleman, thankyou BoB :thumbup

[B o B]

Well, mine's done! :doug How can you go wrong with such detailed instructions? Took me 20 - 30 minutes total. Many thanks P-Peter. Great mod.:thumbup

All I want now is for the weather to clear up, get warmer and go out in the dark. Have you got a mod that will fix that for me Pete?:devious

[rschris]

anyone got a spare diode and soldering iron :D

[B o B]

anyone got a spare diode and soldering iron :D

You are obviously working on the principle of, 'if you don't ask....' etc. I can help you with a diode but not the iron.

[rschris]

ok anyone live near me with a soldering iron :D

[Sprocker]

Well, mine's done! :doug How can you go wrong with such detailed instructions? Took me 20 - 30 minutes total. Many thanks P-Peter. Great mod.:thumbup



Me too, absolute doddle of a job :thumbup

[IanG]

Sod it! Only been on the forum 5 mins and found something to modify already,I can feel a soldering moment coming on :dunno

Ian

[Bear]

Ive just done the switch bridge mod and on my 05 model its the black and green/white wire that needs bridging but all done with HID now:thumbup

[Raptor101]

Taken an hour for both the diode relay mod combined with a £53 Ebay HID H7 kit for the low beam. Still have to locate the ballast and inline transformer which are resting within the fairing, awaiting some velcro purchases to locate them inside the r/h side of the fairing inner (under the r/h mirror). Most of the extra wires ended up inside the headlight recess and a slice in the rubber lamp shrod/plug allowed me to route most of the connectors into the headlamp area. Only snag I've found is that sometimes the bulb won't light up and you need to recycle the ign switch. I an only assume that the batt needs to generate a power spike to a level that 'catches' the bulb before it powers up.
Thanks to the top tips from you guys.
I have a Maplins diode as a spare if any one wants it.
Now just need to wait for it to get dark and properly test ride it.
Cheers
R101

[camngetit]

does the diode have to be that big i have in line diodes from fitting trackers to cars but they are on quite thin wire

[petrolpete]

The diode is only going to have to be able to carry the current absorbed by the coil of the relay, I would guess this to be less than 100mA (most relays are 20mA or so).
So as long as the diode you intend to use is a signal diode and not a zenner diode, and has a low dropout voltage (0.6 for silicon, or 0.4 for Galium), and can handle several 100mA then it should be OK.
To make sure you would have to measure the current on the relay coil to see what they draw typically.(put a meter in series in A mode and see how many amps are drawn).
The only other disadvantage of using a diode with thinner wires is that they will not be as sturdy, mechanically.
Generally most components are over specified so that they do not run at the extremes of their characteristics, so without more info on the diodes you intend to use I can't help any more than this.
Pete (simples, 'innit)

[camngetit]

maplins is only down the road so i popped in today and got 2 diodes 1 for a mate who is bound to want his doing when i do mine not as big as the pics make them look got heatshrink as well all for about £2.50 will do them sat

[camngetit]

just done the diode mod piece of piss works atreat easy great info now for the rectifier wiring

[iamsmib]

Just done this mod too, I found a bag of 1N4006 diodes in a parts bin at work.

Hopefully it won't cause any problems, I they're just rated for higher voltages as far as I can tell.

I'll stick 'em under the seat, ready for all the cheapskates at the next meet. :tounge2 I might even bring a portable soldering iron...but that'll cost you!

Mike.