can anyone give me some info and advise as to what relay and how to install it on my SP500 so all 3 lights will come on at the same time?? i have seen discussions on this on other forums but no info as to what parts and the "how to" install it. thanks.

 

derhtr1,

Here is a copy of part of one of my old posts. It is an easy and inexpensive mod to do. Besides that, the results are awesome. Here goes:

Remove the front rack (4 screws) and pop the hood off. Locate the solid green and yellow wires coming down the handlebars from the headlight switch. Strip a short portion of each wire (1/4"). Attach two diodes side by side between the two wires, with the cathode (line on the diode) end of the diodes towards the green wire. Solder the connections and tape up (or better yet seal with silicone) the bare connections.

The post I got the information from suggested a heavy diode. I agree, to a point. The current that flows through this diode feeds 60w. At 12V this means 5 amps flow though the diode. Therefore you need at least one 5 amp diode. I used two 3amp Schottky Barrier diodes in parallel (side by side). This is the equivalent of a single 6 amp diode. The diodes I used were part number 1N5822T. They cost 47 cents each. They should be readily available at any electronics supply store or radio Shack.

With this arrangement the low position on the switch gives you the two lower lights (as it always did). The high position on the switch gives you all 3 lights at the same time.

This is a great mod for the Sportsman. It is very easy to do, and inexpensive. I have done the mod to 1 '97, 2 '98's, and 1 '99. We don't have any battery drain problems with this arrangement.

DJ

 

hope i don't sound dumb, but do you mean you are "twisting" the 2 diodes together between the yellow and green wires??( i don't think you mean you are CUTTING the wires IN TWO are you??, all you are talking about doing is "stripping" a small place on both wires and twisting the 2 diodes together and attaching them between the two "bare" places on each wire?? thanks. i read on another forum somehwere that talked about putting a "relay" somewhere to accomplish this also. thanks