Guys, is it possible to wire up the hi-beam headlight with the dual 27watt lights located in the front rack to go on at the same time? Can the elec. system handle it? If yes, how to do it. Any UNION electricians out there!

 

I was messing around with my 335 and found if you put the switch between the hi and low position all three lights come on. This way you can have all three options. Low , High and ultra high.

 

Markkh,

I have used this method on a few of the machines in our riding group. It originated here in the forum and works well.

I have tried the method hawk045 mentioned. On my machine it worked fine until I hit a bump!

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 a diode between the two wires, with the cathode (line on the diode) end of the diode 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 a 5 amp diode. I used two 3amp Schottky Barrier diodes in parallel. 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

 

You think this can be done to a Magnum 500?

 

PineyKoJack,

Definitely! Same setup - go for it.

DJ