Suzuki C50 Boulevard Light Bar Install Procedure

Transcription

Suzuki C50 Boulevard
Light Bar Install Procedure
Goal:
Install light bar on Suzuki C50 Boulevard and independant 12v light circuit for
future upgrades.
Before:
After:
Material required:
14 AWG red wire (8ft approx.)
14 AWG black wire (8ft approx.)
20 AWG white wire (4ft approx.)
2 x 1N4001 diodes
1 x automotive relay
Femelle crimp connectors
Male crimp connectors
Heat Shrink Tubing
Flexible wire protector
1 helper for 30 minutes
Tools required:
Soldering Iron
Soldering material
Hex Key 3 mm [ Speedomeeter console ]
Hex Key 5 mm [ Original Windshield Bolt ]
Hex Key 6 mm [ Seat ]
Socket 10 mm [ Gas tank Bolt ]
Socket 14 mm [ Light adjustment Bolt ]
Ratchet
Philip screwdriver
Crimp tool
Electrical wire cutter/stipper
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Page 1/9
Step 1: Electronic circuit
Prepare the “OR Gate” circuit as above that will enable the relay when either the low or high
beam is “on”.
14 AWG red wire – Used for +12V battery wire.
14 AWG black wire – Used for GND battery
wire.
20 AWG white wire – Headlight low beam
signal.
One easy way to solder the diodes: Directly on
wires and covering them with heat shrink
tubing.
Page 2/9
Installing the new lights:
STEP 1: Removing existing windshield hex bolts.
2 x 5mm Hex bolts per side.
You can use a ratchet or long handle
hex tool / screwdriver.
STEP 2: Install the new lightbars 1 per side.
I had crimped the wire with female connectors before installing.
Replace the original windshield bolts
with the ones provided in the kit.
I have used the “spacer” in between the
light bar and the windshield frame.
Page 3/9
STEP 3: Acccessing the battery compartment.
A) Remove Seat by removing the 2
B) Lift seat and pull away from the gas
6mm hex bots at the rear of the seat.
tank.
On some models you have to move the
chrome rack away (careful not to
scratch paint !)
C) At this point you should get this:
D) This is what it should look like once
everything is done. (a few steps later)
Welded-on 1 /4 ”
ring c onnec tors
Welded-on 1 /4 ”
ring c onnec tor and
1 0 A fus e and fus e
holder
Note routing of wires to avoid seat framing once
the seat is reinstalled.
Page 4/9
STEP 4: Lifting gas tank to route wires.
[ At this point your need a helper to lift gas tank ]
A) Remove speedometer console by
removing the 3 x 3mm hex nuts.
Remove speedometer connector –
unclip using finger or screwdriver. Be
careful not to break anything - fragile.
B) Set the speedometer aside in a towel
outside of work area.
C) remove the main gas tank 10 mm
bolt.
D) Have your helper lift the tank about
4” up in the air without disconnecting
the gas line.
Page 5/9
STEP 5a: Routing wires (gas tank)
From the battery, run the 1 or 2 wire at Run near the main wire harness.
at time. I later used plastic wire
protector.
Run wire above engine as far away
from direct engine contact.
Make sure nothing is in the way of gas
tank, once it will be reinstalled.
Page 6/9
STEP 5b: Routing wires (via fork)
Remove ignition key cover by pulling
... remove left hand side cover by
out and lifting (fragile). Run wire at the pulling out and lifting (fragile) and run
back of the ignition switch...
wires out on the other side of the fork...
... and finally end the wire inside the
headlight housing.
•
•
•
•
•
•
Reinstall ignition key cover.
Reinstall left hand side cover.
Tie wrap everything.
Reinstall gas tank.
Reinstall speedometer bezel.
(Don't tight hex screw too much
or bezel will crack!)
Leave wires unconnected to
battery for now.
Page 7/9
STEP 5b: Splicing the headlight wires
(Low beam = White wire – same process for high beam = Yellow Wire)
Make sure to protect fender with old cloth.
Cut wire with enough wire to resolder.
Attach an extra piece of white wire (20
AWG) and a female connector. This will
connect to the diode “OR GATE”.
Strip wire, insert a heat shrink tubing
on wire. Attach the 2 ends of old wire +
new wire together and solder.
Heat Shrink
Tubing
Low beam signal connector installed
and heat shrink tubing in place.
Connect all wires to relay.
Connect battery. Test.
Splitted
Headlight
Signals
Diodes OR
Gate
Relay
Page 8/9
STEP 6: Closing everything up
Battery wires should be wired as follow
before reinstalling gas tank and seat.
Connects all wire, bundle with tie-wraps
and close headlight. Tie-wrap wires
coming out of the new light bar to the
frame as required. Adjust light height
by loosing up the light bar bolt
(14mm). Retight once everything is
completed.
Installation Completed!
Page 9/9

Suzuki C50 Boulevard Light Bar Install Procedure

Transcription

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