Swapping to FZS400 reflectors

[Clampy]

Hi, I’m new to the forum which I originally discovered when researching ways to improve my FZS600 (2000) headlights. I’ve aquired a damged FZS400 unit with intact and ‘un-burnt reflectors with a view to swapping for the originals and doing the headlight mod suggested on this site. That way I could retain my sidelight for MOT purposes. Has anyone done this before? I’m happy to heat-up the units to separate them for the swap, but am less confident about the ‘wiring’ part. Any hints and advice would be gratefully received! I also have the FZS400 loom for the unit; could this be used? 

[unfazed]

Is the rear of the 400 headlight intact? If so you can use it with the 600 front.
Makes it easier as the rear will have the holders to take the H4 bulbs. but you will need to drill a hole to take the parking light
If you use the 400 rear of the light unit, the standard H4 bulbs will need to have two of the location tabs cut off to fit the 400 holders.
 If not you will have to modify the left holder of the 600 light unit to take a H4 Bulbs

Let me know what you are doing and I will go through the rest with you

[Clampy]

Thanks for the quick reply. The plastic back part of the unit is missing 2 lugs, so I was hoping the reflectors would locate in the FZS600 item. The reflectors are intact with original bulbs fitted. I thought it would be just a matter of spitting the unit and removing the reflectors to swap with the originals. The bolt positions look identical...Many thanks, and I’ll let you know how I get on in the next couple of days.

[unfazed]

If the the bulb holder is part of the reflectors then there will be no problem swapping tham and you wil keep the parking light. I am working from memory as it has been a while since I saw the Box eye or 400 headlight.

[daviee]

split the light the reflectors are held on by two adjusting screws and a ball and socket that pops off the bulb holders are part of the reflector

[unfazed]

You are going to have fun adjusting the lights, make sure you have a good battery.
Try and measure the heights from the back of the unit to the front of the reflector.
Top and one side will be sufficient on each reflector.
Make setting the light a bit easier

[unfazed]

Forgot to add in previous post. Iis there a Black/blue wire going to both headlight connectors to the large connector on the 400 loom.
Post a pic of the loom showing the headlight connectors and the large connector.

[Clampy]

Thanks for all the help guys. Apologies for not replying sooner (just started a new job). Have swapped the reflectors after much swearing and they seem to fit but will need to be pointed a bit higher (wish I’d measured their old positions first as suggested..oops). The 400 loom matched regarding connections but were mixed-up in operation, full beam and dipped on at once on one side in the dipped position. Think I’ll stick with the original and do the mod; that way I’ll retain the feed for the sidelight. Another thing I overlooked was the sidelight position. The reflectors project further forward so I will need to either trim back the RH side or reposition the holder further forward. It’s proving a bit of a pain but I’ll get there in the end; hopefully!!
Any other suggestions would be gratefully received and I hope to get back to you sooner this time.
Cheers

[unfazed]

Forgot to add in previous post. Iis there a Black/blue wire going to both headlight connectors to the large connector on the 400 loom.
Post a pic of the loom showing the headlight connectors and the large connector.

Do this and I will help sort out the wiring. The mod wont help you and you are better using the 400 loom. You will need to change where the green wire on the loom to the headlight come from. Trace this wire back and let me know