HOW TO: Install a headlight modulator

Outstanding work on your tutorials gam..Im enjoying it good work again and thanx.

 

Your mod is awesome, but there is another circuit you need to add to make it legal...at least here in Canada. You have to have a way of disabling the modulator after the light levels (dusk) drop below a certain number. In the Transport Canada Regulations as of 2007, here is the latest on modulators for motorcycles. Please check with the US department of transportation to see if this also applies. I ended up buying a modulator off the internet and swear by it. In the 3 years I've used it, I have not had an oncoming vehicle cut me off. I've had many cops stop me to ask where they could buy one for their personal rides! Might seem expensive, but my life is worth more. Here's the article from Transport Canada outlining the requirements for an installed modulator.

Technical Standards Document No. 108, Revision 4 — Lamps, Reflective Devices, and Associated Equipment
See this link: Section S7.9 Motorcycles
Effective Date: June 9, 2007
Mandatory Compliance Date: December 9, 2007


S7.9.4 Motorcycle headlamp modulation system

S7.9.4.1 A headlamp on a motorcycle may be wired to modulate either the upper beam or the lower beam from its maximum intensity to a lesser intensity, provided that:

(a) The rate of modulation shall be 240 ± 40 cycles per minute.

(b) The headlamp shall be operated at maximum power for 50 to 70 percent of each cycle.

(c) The lowest intensity at any test point shall be not less than 17 percent of the maximum intensity measured at the same point.

(d) The modulator switch shall be wired in the power lead of the beam filament being modulated and not in the ground side of the circuit.

(e) Means shall be provided so that both the lower beam and upper beam remain operable in the event of a modulator failure.

(f) The system shall include a sensor mounted with the axis of its sensing element perpendicular to a horizontal plane. Headlamp modulation shall cease whenever the level of light emitted by a tungsten filament light operating at 3000 degrees Kelvin is either less than 270 lux (25 foot-candles) of direct light for upward pointing sensors or less than 60 lux (5.6 foot-candles) of reflected light for downward pointing sensors. The light is measured by a silicon cell type light meter that is located at the sensor and pointing in the same direction as the sensor. A Kodak Gray Card (Kodak R-27) is placed at ground level to simulate the road surface in testing downward pointing sensors.

(g) When tested in accordance with the test profile shown in Figure 9, the voltage drop across the modulator when the lamp is on at all test conditions for 12 volt systems and 6 volt systems shall not be greater than 0.45 volt. The modulator shall meet all the provisions of this TSD the standard after completion of the test profile shown in Figure 9.

(h) Means shall be provided so that both the lower and upper beam function at design voltage when the headlamp control switch is in either the lower or upper beam position when the modulator is off.

For more information, contact:
Motor Vehicle Standards and Research Branch
Road Safety and Motor Vehicle Regulation Directorate
TRANSPORT CANADA
Ottawa, Ontario
K1A 0N5

 

yes, this definitely MUST get onto the next XJCD!

 

US DOT regulations also require that the light not be modulated after dusk.

 

Also note, with a headlight modulating, the headlight will burnout prematurely too because of the constant on and off. The filemant is not designed to handle it.
I've heard several riders complain about their headlight burning out all the time until they mentioned they had a modualtor installed, so that's my conclusion. PD

 

Gotta be a decent replacement somewhere?

 

In my 3 years of using the headlight modulator, I have never changed the bulb, which is a good quality Sylvania Silverstar one. The modulator is a definite safety feature on any bike, regardless of any burnt bulbs.

 

too bad a headlight modulator is prohibted over here in NL.
Flashing headlights is for Police, ambulance and Firefighters only...

Some cops do "allow" it (especially the cops on bikes) , most don't

Over here the running lights (constant low shinging of the blinkers) is somewhat allowed (still not legal) this works out for safety for the better part. That's because cars don't have runninglights too...

 

Headlight modulators have the following legal requirements per the federal DOT.

1. Must modulate the high beam.
2. Must modulate at the frequency of 2.4 hz (4 times / sec)
3. Must have a mechanism which automatically switches the modulator off dusk through dawn. Generally a photo sensor set for 65 lumens.
4. Must be installed on the power lead going to the headlamp and cannot be wired to the ground side of the circuit.
5. Must have an on/off switch in case of device failure
6. When modulating, the headlamp cannot drop below 17% of regular power ... Some approaches flash the headlight instead of modulating it. Not only is this illegal, but it will quickly burn out your bulb, where as modulation will actually extend the life of your bulb.
7. Bulb must be on full power 50% to 70% of the time.
8. If light sensor faces down, it must turn off the unit at 60 LUX. If facing up, it must turn it off at 240 LUX.

The commercial units are way over priced. They should make the price reasonable and sell greater quantity rather than charging premium prices for something which should actually be mandated on all new production.

 

Gamuru, this is my next project!

thank you so much!

kinen1

 

Please let me know when you have done this. I would love to see the plans. I don't have any knowledge of circuits and such. I tried to get my brother to help me, he is an accomplished engineer who has designed things like battlefield communications systems. Unfortunately, he never came through which is highly unusual for him.

I didn't think it would be that hard. It should be something you can piece together for under $15.

 

XJ4Ever has a couple of different styles of plug-n-play headlight modulators available. I've been working on a photo "how to" of the installation possibilities, and it's nearly ready.

Stay tuned.

 

Where are these modulators on XJ4Ever? I just searched all 6 pages of the catalog for the word "modulator" and came up empty.

 

Seriously?

When was the last time our good buddy Len actually updated his catalog? '09???

He's got all sorts of neat stuff available that's not in the "catalog." Caliper pin boots, instrument pod and detail decals, square rubber relay hangers, all kinds of neat stuff. You simply have to ask him.

C'mon, man. Send him a PM.

BTW, headlight modulators work. I honestly (and quite accidentally) "balked" a FIRE TRUCK with lights and siren a'blazin' because I was approaching and he was going to have to turn left in front of me. I stopped and shut the modulator off, of course. Plus, they're irritating as heck to automobiles in front of you (sorry lady, survival device. Hang up the phone and drive.) It's a great "left lane broom." You wanna run 80 on the superslab and there are people sleeping in the left lane at 68? They'll move over.

I'm totally convinced they work; at least so that other drivers at least register you in their brain as being there. Whether or not they then make a conscious decision to pull into your path is a different story; at least with your modulator on they know you're there. And I'd rather survive than worry about irritating a few smartphone users who happen to be driving a car.

 

I know they work. That is why I want them so seriously.

I didn't realize he was so far behind on keeping his catalog up to date. How are we to know what he has if they aren't listed in a the catalog?

 

I know they work. That is why I want them so seriously.

I didn't realize he was so far behind on keeping his catalog up to date. How are we to know what he has if they aren't listed in a the catalog?

 

Or an email.