Hi all


Where is the best place to locate headlight relays? - don't want to dismantle more than I need to!

Thanks, Mike

Hi Mike,
I have recently installed them on my '85 RT. I bought relays with an integral fuse, so I mounted them outside the relay box, either side of the fuses. 
Removing the tank will allow you access to the starter relay, which is where I sourced the power. It also allows easy access to the frame area to run the wires neatly.

Regards,
Bill

have a look for the "eastern beaver" headlight relay kits

buy all accounts a good solution for all those that are unsure ...or just want a good solution premade

personally I have mounted a few setups off  a bracket that I made  off the horn bracket on the left hand side of the fairing internals

like the eastern beaver kit ..I have used the current headlight (h4 ) connector as a socket for 3 spade type plugs to then go off to the relays as switching signal

power from the  input connection to the starter relay ..via a fuse before it connects to the relays maintains some form of short circuit protection

I have done a couple now .....one of them had the relays in the fuse box all neat and compact

try the search feature "headlight relays " 

you will find an immense amount of posts on this subject for your research

good luck and a very suggested modification

Thanks guys!

At present mine are just neatly tucked in with the various connectors under the tank. I plan on mounting them in the relay box at some point.

I copied the eastern beaver kit (with the exception that mine is now 'hard wired' into the bike, rather than utilising the existing H4 socket) I basically got it right first time but spent ages annoying my self and others trying to figure out why it wouldnt work. Turns out one of the other relays in the relay box was not working and therefore the headlights would not work. May have been the flasher relay, I cant recall. (just to clarify, I am not talking about the new headlight relays here - Im talking about a pre existing relay in the relay box not working)

Anyways, point is, if your going to go DIY, it would be easier for you if the headlights are known to work before you begin cutting cables up. That way when you connect it all up and it doesnt work, you know the problem is with your work, not some pre existing problem - makes troubleshooting that much easier and faster.

This is what Charlie knocked-up for me...

He made up a small bracket and attached the high beam and the low beam relays to it.

Marvellous work!

I used two 1FormA PC-mount relays on a perf board with solder-on spade connectors for mine.  Fits neatly in the relay box and I feed 12GA stranded wire to a ceramic H4 lamp socket in the headlight housing.
Top side:

Bottom side:


Installed:

Hi Rob - nice solution! Time to get the soldering iron out I think!

Thanks, Mike