Accessory Relay Kit Installation

Please read these instructions all the way through before beginning installation!

Description: These kits hookup to the bike's battery (or fuse panel), the accessories, and an ignition switched lead on the bike.

Preparation:  Do not put a fuse in the Kit's fuseholder until you are finished the install. You will be connecting to the bike's battery and you don't want the red (hot) wire to cause a problem when it's connected. Remove any bike parts needed to access the battery area and your planned wire run to your accessories.

Relay and Wiring Installation: Decide where to mount the relay near the battery, by laying the kit out in the planned position. Stretch out the battery wires to the battery area and locate the relay leaving a bit of extra slack in the battery wires. Do not connect to the battery now, leave that for last. Choose a relay location that's protected as much as possible from rain and dirt. Attach the relay in its location with a tie wrap, a screw, or a nut and bolt. Route the switching wire and accessory wires to where your switched lead and accessories will go. The relay and wiring should be tucked and tied into the existing wires on the bike, or any convenient location.

Accessory Installation: Now mount your accessories before attaching the Kit's main leads to the battery. Make sure no wires will rub anywhere, or be pinched by the gas tank or the handlebar's full range of movement. Connect your socket with the T-Connector, and any accessory to be hard wired to the Posi-Locks. Complete the accessory end of the install by tying up all wiring carefully.

Ignition Switched Lead Install: If you don't already know where to find an ignition switched lead, you'll have to do some testing. However, there are many internet bike groups with the information you need to find the best wire for this purpose. I suggest you find out and make this job easy. The Posi-Tap on the end of the Kit's relay switching wire is easy to install and will not damage a wire. Please look here to see how to install a Posi-Tap. You'll have to remove the Posi-Tap before installation on the wire to be tapped.

If you can't find any info online as to where to find an ignition switched wire on your bike, you can use a parking light hot wire, a tail light hot wire, a brake light hot wire, or any other hot wire which goes on and off with the bike. Use your bike's wiring diagram to identify wires by their color. You may have to follow the wires from your rear brakelight switch (for example) up to where you'll likely find a connector under the seat or tank.

Battery Hookup:  See notes at the bottom of this page. First remove all wires from the bike's negative battery post. Never loosen or remove wires from the positive battery post first! Make sure the negative wire(s) will not touch the negative battery post during the battery hookup.  Now remove the battery bolt from the red positive wires from the bike's battery. Place the Kit's fuseholder ring terminal on top of all other terminals that were on the battery positive post, reinsert the bolt through all wire terminals, and tighten it back up snugly.

Note that there is likely a rubber cap on the positive battery terminal. Try and route all the wires so that this cap can remain in place to protect the post and wire terminals. If necessary cut a small slit on the side so that the new wire can exit in the direction that you want it to.

Now the Kit's black battery wire goes on top of the negative leads you took off the battery negative post earlier. Install the bolt for the negative post through all the wire terminals and tighten it up snugly. Make sure all connectors are clean before reinstalling! Negative battery terminals are the ones that tend to have corrosion on them. Do not install a fuse in the Kit's fuseholder yet!

Testing:  Go back over all your work carefully, and before adding a fuse or plugging in anything to a power socket, test that you can hear a soft click from the relay when you turn on the bike. You may have to move your ear close to the relay to hear it. This tells you that the relay is properly connected and working. Now put a fuse into the Kit's fuseholder and check that the accessories are working. Do not leave your bike's ignition on without the bike running for any longer than you have to for these tests.

Finish: Now replace everything you took off the bike for the install, start the bike and check that everything is working. You're done!

Other Notes: Battery connectors do corrode over time. Special grease is available to avoid this. If you find your battery terminals are covered with some of this grease, you must clean and remove all of this material before reattaching any wires. Then reapply it if desired, when you're finished. Make sure any battery terminal shields are not broken, and are properly replaced when finished. Battery connections that are not covered with grease should be removed and cleaned yearly, so don't avoid this important step. Check the routing and condition of all your bike's wiring as you go.