Hmm, just when I think I got it figured out, it seems I dont! If you could take a look at this CBR1000RR wiring schematic below. The best I can figure this out - the headlight hi-beam relay only gets activated when the dimmer switch is toggled to high beam. Where is the relay for the low-beam line? I'm trying to figure out what part I'll need to order if I do need to run a relay. I took a look at your build .. looks amazing! (And your electrical expertise far exceeds mine own.)
https://dl.dropbox.com/u/7792046/CBR1000RRWireDiagram.jpg
https://dl.dropbox.com/u/7792046/CBR1000RRWireDiagram.jpg
neevo said:Not quite. On modern bikes the single switch activated a 5 pin relay which switches a single input (power) across two outputs (low & high beam). The switch in the handlebars runs power to the relay to switch across the two outputs.
On my CB400F project I used R1 controls, a 5 pin relay and a custom wiring harness for the headlight switch. Headlight doesn't come on with ignition (to save battery power), its only activated when the bike is put into run.