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LEGAL NOTICES

The information in this document is not a substitute for technical skill and proper tools. It is presented for information and entertainment purposes only. Neither the website host, the publisher nor the author accept any responsibility for the accuracy, or appropriateness of this information to any application. You assume all risks associated with the use of this information, and neither the hosts, publishers, nor authors shall be liable for any direct, indirect, punitive, special, incidental, or consequential damages arising out of or connected with the use or misuse of this information, whether specified, implied, or omitted. Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. Even if performed correctly some modifications, including those described herein, may endanger the safety of you and others and possibly invalidate your manufacturer’s warranty.

Installing Passing Lamps w/Toggle -- by randysgym,

©Randy Fox, St Louis, MO USA, 2012 -- All rights reserved

Page 1 of 25

Introduction
It's really not that hard to wire your bike for passing lamps, but if you haven't done much wiring before, give yourself plenty of time -- like at least a full weekend or two. Buy all the materials and tools you will need ahead of time. If you take your time to do it right, you'll have many years of trouble free service. You’ve got two decisions to make before you start wiring. First, you need to decide how you want your new lamps to operate. Various options are listed below, in order of increasing functionality. 1. Lamps always on -- This is the simplest wiring. No toggle switch is needed. 2. Lamps go on and off with the headlight dimmer control -- This is just as simple to wire as the first option. No toggle switch is needed. 3. Lamps controlled with ON/OFF toggle switch -- This has two more wiring steps than either of the first two options. The lamps are switched independently of the headlight dimmer control, and would not be safely switchable while riding. 4. Lamps toggled UP to stay on, or DOWN to go on/off with the dimmer control -- This has only a few more wiring steps than Option 3 above. A 2-position, DT (dual throw) type toggle switch is needed. 5. 3-Way Setup -- This is wired and operates the exact same way as Option 4 above, except it uses a 3-position toggle switch. The middle switch position allows for a lamps-stay-off capability. Option 5 is what I use. When I get my vehicle safety inspection, I can set the toggle so the lamps go on and off with the headlight dimmer. Then, once the inspection is done, I can toggle the lamps to remain on all the time. I don’t remember the last time I switched the lamps to stay-off, but it’s nice to know I could if needed. Before jumping in, you must also decide on a power source for your lamps. Do you want to run a separate wire, protected by its own fuse and switched via a relay? Or are you agreeable to just tap into your bike's existing headlight wiring as Yamaha's Passing Lamp Kit instructions recommend? The general flow of this document is based on the second choice -- tapping into your existing headlight wiring. However, if your new lamps might tax your wiring circuit see Appendix-A near the end of this document. You may also wish to view Appendix-B on the last page of this document to more effectively ground your lamps.

Installing Passing Lamps w/Toggle -- by randysgym,

©Randy Fox, St Louis, MO USA, 2012 -- All rights reserved

Page 2 of 25

This wire goes from the two power leads (wires) from your passing lamps. they tend to be way too small for 16 gauge wire (at least the ones I've seen). It will allow you to disconnect your passing lamps from the bike’s stock wiring.to connect to the wires to the switch. This is only needed if the wiring option you choose is Option 3. 2012 -. the result will be the maximum watts the switch can handle. MO USA. especially if you put a dab of silicone adhesive or RTV silicone on the screw threads to lock them in.3 feet if you'll be mounting a toggle switch in one of the passing lamp shells. Personally. This is the alternate power source for your lights if you intend to use Option 4 or 5 from Page 1.All rights reserved Page 3 of 25 . I believe it makes for a more trouble free connection.  RadioShack® Star Ring Terminals 16-14AWG (10-Pack). as desired. and length of each wire is as follows:  Power Source In wire -.unless you will be soldering your connections. Get 2 feet -. I believe screw terminals are the most secure. Power In wire -.4 feet if you'll be mounting a toggle switch in one of the passing lamp shells.  Dual Source.Recommend yellow or Red. Selecting a toggle switch If you will be using a switch be sure it’s rated for at least 12 volts and at least 6 amps (9 amps if your lamps are greater than 35 watts each). Switch Selection Tip: I also recommend using a switch with screw or spade terminals. Get 2 feet -. part# 64-3118 …OR…  RadioShack® Solderless Insulated Spade and Ring Tongues (75-Pack). Tip: If you have an electrical problem in the future. I don't like solder terminals for two reasons: First. For example: RadioShack® 1/4" Fully Insulated Quick Disconnects (10-Pack). part#: 64-407 Heat-shrink tubing or electrical tape or (my favorite) liquid-tape -. and is only needed if you intend to use Option 3. Get at least 2 feet -. This is optional but recommended.for covering contacts and connections. To get technical about it.or other type. proposed color. part#: 64-3133. Spade connectors -. all three broke at the terminal after a just a few years' time. Pick ONE. multiply the amp-rating times the voltage rating.Materials Needed You'll need 16 gauge.Recommend white or a color to match or compliment the passing lamp wire colors.4 feet if you'll be mounting a toggle switch in one of the passing lamp shells. This is the wire to supply the main power for your lamps. you can more easily isolate the problem by simply unplugging components.by randysgym. 4. ©Randy Fox. Remember to double the wattage. Then check the wattage of your passing lamps (25-35 watts is common). I recommend you create quick-disconnect connections for every electrical add-on you install. Ring connectors -. stranded copper wire. Second. as there are two lamps. St Louis. I've used three different solder terminal toggle switches for my bike. ideally in several color coatings. flexible.Recommend red or white. part#: 64-043 …OR…  RadioShack® #8 Insulated Ring Terminal (16-Pack). or 5 from Page 1. 4 or 5 from Page 1 and the toggle switch you install has screw terminals. The usage. and so you may want two or three colors of wire. Installing Passing Lamps w/Toggle -. If your soldering skills are good. I prefer to solder. The following are three examples that would work fine. they don't seem to withstand long-term vibration without cracking or breaking. Splice or Tap connectors -.  Power Out to Lamps wire -. Your wire will be needed for two or three purposes.

 2-Position (On/On) toggle switch -. It allows great control and fits in very tight places. Fits Standard 1/2" Switch Stem. very heavy duty switch with six screw terminals.for removing/installing the headlight lens assembly. from the choices listed on Page 1. heated grips. The first example is the one I use.All rights reserved Page 4 of 25 . 10mm socket wrench or equiv -. Tip: I use a Craftsman Bit Ratchet Screwdriver. or much worse. Push the limit too close. MO USA. from Ace Hardware. (Thus. dual throw) switches with screw terminals rather expensive. from the choices listed on Page 1.for removing the headlight shell. part#: 2751533. This is appropriate if the wiring option you choose is #3. from the choices listed on Page 1. and over time your wiring can become stiff and brittle.JT&T Products (2643F) . Do not just use pliers. especially with a center-off position. 8mm socket wrench or equiv -. I use 25 watt passing lamp bulbs.15 AMP @ 12 Volt . Tip: A DP (dual pole) switch is overkill. Phillips screwdriver -.SPDT. At the minimum. Here's an alternative that costs a couple of bucks: JT&T Products (2659F) . This is appropriate if the wiring option you choose is #4. from the choices listed on Page 1. no ring connectors needed). wiring. St Louis. 2012 -. heavy duty marine switch with three screw terminals. This includes all lights. heavy duty marine switch with three screw terminals. connectors) does not strictly adhere to tidy numeric formulas. long-lasting. Not needed if you’ll be crimping your connections. This is appropriate if the wiring option you choose is #5. Installing Passing Lamps w/Toggle -. See craftsman.com (or other similar) for details or alternatives. But be very careful running too close to the rated limit.  3-Position (On/Off/On) toggle switch -. You only need ONE.  On/Off toggle switch -. The real world of electrical components (fuses. This is appropriate if the wiring option you choose is #5. the headlight fuse is rated for 15 amps. you might consider installing a protective rubber boot over the exposed switch lever.by randysgym. ©Randy Fox. as needed to install your passing lamps and wiring. trouble-free connection.Important Wattage Tip: I recommend drawing no more than about 80-90 watts in aftermarket accessories on the headlight wiring. GPS. I got one for a few cents at a local electronics components shop.25 AMP @ 12 Volt .Toggle Weatherproof Switch Boot. item #00941716000. The following are examples and possibilities. radio. which equates to 120 watts of potential accessory use. like one listed above. Important Note: Do not use plumbing solder. and anything else that might be wired into the headlight fuse wiring.SPDT.25 AMP @ 12 Volt .for removing the turn signal light assemblies. Soldering iron and electrical solder -.RadioShack® DPDT 10-Amp 125-volt. use something like the GB® Light Duty Crimper (GS-388). but I have found SPDT (single pole.Optional. as needed.JT&T Products (2941F) .JT&T Products (2644F) . accessories.) Yes.SPDT. Bakelite with Integrated Wire Leads (which means.  3-Position (On/Off/On) toggle switch -. Tools Needed Crimper/stripper -.Not needed if you’ll be soldering your connections. They don’t have the right kind of jaws to create a secure. If you will be using a toggle.

2. that means the following: 1.for dimpling your drill hole. Installing Passing Lamps w/Toggle -. cover the front fender. and floor area with soft. it will still be attached via a wiring harness. wheel. 9.All rights reserved Page 5 of 25 . but only if. Do this by bending open the two wire harness restraints in the shell to allow the wiring to move freely. Then. at approximately the 4 o’clock and 8 o’clock positions. 8. if you will be putting in your own toggle switch. disconnect the brown. and specifically for the Road Star.Drill and appropriate size. 3. and lifted up and off the headlight shell. you will be removing the turn signal bar on your Road Star. Also. pull off the chrome-plastic cover just below the headlight. MO USA.if you will be putting in your own toggle switch. Caution: There are thick spacers beneath the bolts. If the turn signal light bar is to be removed for your kit. unscrew the two retaining bolts holding the bar -. To do this on the Road Star. unscrew the two phillips-head screws at the sides of the bezel. In general. Center punch -. in preparation to install the new parts. First. making clear note of where each harness enters the shell. Now unplug the wiring connector at the rear of the headlight lens. 5. Any parts or tools dropped can scratch and dent themselves and/or the bike. and use caution as you pull the shell free of the wiring harnesses. loosen or remove the two remaining 10mm bolts from the inside of the shell. thick padding. Keep track. fork. Remove the headlight lens/bezel assembly. 6. ©Randy Fox. Disconnect at least one terminal of the battery. but the lowest one is a different length.they are located near its center area -. However. if they fall. two of the bolts are the same. If the shell is being removed. If. They can easily fall out when removing the shell. Taking Things Apart Follow the disassembly instructions for your kit. The next step disconnects the harness.and remove the bar. high-speed drill bit -. depending on your lamp kit. 4. Wiggle the headlight shell loose or off. St Louis. green. or get lost. Be careful they don’t scratch or dent anything. they are headlight aiming screws. Now the bottom of the bezel can be swung out a little. remove or loosen the entire headlight shell. If the turn signal bar is to be removed. Then remove the 10mm bolt from the lower-center area inside of the shell. in the center of the turn signal bar. 2012 -. Tip: DO NOT unscrew the forward-facing. 7. and black turn-signal wiring connectors. deep-set screws in the bezel.by randysgym.

But it does help. Next use a center punch to mark the hole’s center.  Once the amber light assembly is completely free of the bar. Some passing lamp kits come with a predrilled hole in one lamp shell. note from which side -.but only one at a time. The paint is just for rust protection. Installing a Toggle Switch Decide where you want the switch. MO USA. Be careful not to pinch or stretch the wiring inside. and drill the mounting hole.10. See photo right. as desired. Installing Passing Lamps w/Toggle -.left or right -.by randysgym.  Wiggle and pull the assembly free of the turn signal bar. Protection Tip 1: In the photo right. So I wire brushed all the rust and scuff the remaining finish. Rust Prevention Tip 3: I had noticed that after several years of normal riding. First it needs to be wired. so it can be used on the same side when reused. my headlight shell was showing some signs of rusting inside. As you extract the light assembly. The tape is not power tool proof nor impact proof nor fool proof. Do not install the switch yet. St Louis. such as with the Yamaha Passing Lamp kit.the light came.  Perform the same removal process on the other light assembly. Many riders install the switch in one of the passing lamp shells.All rights reserved Page 6 of 25 . Reinforcement Tip 2: As seen in the photo. if one will be used. ©Randy Fox. I covered the outside of the headlight shell with blue painters tape to protect it from scratches while I worked on it. help the wiring connectors at the center of the stock turn signal bar to exit without undo stress on the wires or connectors. 2012 -. I glued the on/off switch plate that came with my toggle switch to the inside of the headlight shell to help add thickness and strength around the hole. Then I brush painted with a protective silver paint. Caution must still be exercised however. do the following:  Remove the 8mm bolt/nut for both light assemblies -. Note: I put my switch in the left-rear of my headlight shell. If your stock turn signals are to be reused without the bar.

Installing the Light Bar and Lamps Now you must follow the hardware (non-electrical) installation instructions for your kit. -. bars. ©Randy Fox. Tip: Remember those bolt spacers. MO USA. Installing Passing Lamps w/Toggle -. etc. See diagram below for guidance. do this now. but do not re-secure them to the in-shell restraints yet.by randysgym. 2012 -.lights. St Louis. assuming it was removed. if the headlight shell was removed.All rights reserved Page 7 of 25 . If the instructions have not already had you replace your headlight shell. Be sure you get all the wiring harnesses fed back into their original holes. to get all the new components -.in place.

right.Wiring the Lamps and Maybe a Toggle Switch Depending on which Operation Option you chose from Page 1. use a splice or tap connector or solder the other end of your tap wire to a convenient spot on the bike’s red/yellow wire. Locate this power wire inside the headlight shell and splice/tap into it. St Louis. follow the instructions in the appropriate section below. Installing Passing Lamps w/Toggle -. red/yellow. ©Randy Fox.All rights reserved Page 8 of 25 . striped wire as its 12 volt. See diagram. MO USA. Crimp or solder a female spade connector onto one end. cut a 3 inch. It does this via spade connectors so you can always disconnect your lamps if you need to. alwayson-when-the-ignition-is-on. or so. Option 1: Lamps Always Stay On -. The Road Star uses a twocolor.by randysgym. piece of the wire you will use as your POWER tap wire. Next. power wire. | | | | To make this tap wire. 2012 -.No Toggle This option simply connects a POWER wire directly to your passing lamps.

Installing Passing Lamps w/Toggle -.by randysgym.At this point you’ll want to be sure you have the power leads (the wires) for both passing lamps terminating together in the headlight shell. Locate that wire in the wiring harness that plugs into the back of the headlight. leaving at least 3 inches of free-end length on one wire. and proceed to Finishing Your Installation. St Louis. The Road Star uses a yellow wire as its highbeam power wire. Now use a splice or tap connector or solder one of the leads to the other one. 2012 -.No Separate Toggle Switch This option simply connects the HIGH-BEAM wire directly to your passing lamps. Plug this spade connector into the connector you previously made for the power wire. Option 2: Lamps Go On/Off With the Headlight Dimmer Control -. Then crimp or solder a male spade connector to the remaining free end. right. ©Randy Fox. MO USA.All rights reserved Page 9 of 25 . Then splice/tap into it. It does this via spade connectors so you can always disconnect your lamps if you need to. See diagram.

©Randy Fox. leaving at least 3 inches of free-end length on one wire.by randysgym. Then crimp or solder a male spade connector to the remaining free end. piece of the wire you will use as your HIGH BEAM tap wire. See diagram. 2012 -. Next. Installing Passing Lamps w/Toggle -. Now use a splice or tap connector or solder one of the leads to the other one. See diagram. Plug this spade connector into the connector you previously made for the high-beam wire. St Louis. use a splice or tap connector or solder the other end of your tap wire to a convenient spot on the bike’s yellow wire. Crimp or solder a female spade connector onto one end. right. and proceed to Finishing Your Installation. cut a 3 inch. right. | | | | | | | | | | | | | | | | | | | | At this point you’ll want to be sure you have the power leads (wires) for both passing lamps terminating together in the headlight shell. or so. MO USA.To make this tap wire.All rights reserved Page 10 of 25 .

Heat-shrink or tape exposed areas of the connector as needed. power wire. Next. The Road Star uses a two-color.Option 3: Lamps Turn On/Off With a Toggle Switch This option simply connects a POWER wire to your passing lamps via a simple on/off switch. 2012 -. See diagram. | | | | To make this tap wire. ©Randy Fox. Crimp or solder a female spade connector onto one end. MO USA. Installing Passing Lamps w/Toggle -. piece of the wire you will use as your POWER tap wire. or so. cut a 3 inch. the back of your switch has two terminals:  Power in  Power out Be sure you orient your switch in the direction you want. Be sure you heat-shrink or tape the exposed wiring.All rights reserved Page 11 of 25 . If this is the option you want to use. right. Locate that wire inside the headlight shell and splice/tap into it. St Louis. Spade connectors are used so you can always disconnect things if you need to later on. striped wire as its 12 volt.by randysgym. use a splice or tap connector or solder the other end of your tap wire to a convenient spot on the bike’s red/yellow wire. red/yellow. Most will want ON to be in the UP position. always-on-when-the-ignition-ison.

covering exposed areas of course. crimp or solder a ring-connector (assuming your toggle has screw terminals). See diagram. Installing Passing Lamps w/Toggle -. Since my toggle switch is in the headlight shell. Now use a splice or tap connector or solder one of the leads to the other one. Then crimp or solder a ring-connector (assuming your toggle has screw terminals). To do this.by randysgym. 2012 -. Be sure you heat-shrink or tape exposed areas of the connectors as needed. Crimp or solder a male spade connector onto one end. or a spade connector (if your toggle has spade terminals) to the other end. Tip: If your switch is going to be in one of the passing lamp shells. St Louis. but do not plug the spade connectors together yet. See the orange wire in the diagram.Now make the corresponding wire segment for the toggle switch. Example: If your toggle switch will be in the left passing lamp shell then the leads for BOTH passing lamps must terminate to the rear of the left shell. leaving at least 3 inches of free-end length on one wire. Now the only remaining wiring is to make a corresponding wire segment for the toggle switch. See diagram. but do not plug the spade connectors together yet. Then crimp or solder a male spade connector to the remaining free end. you may need to route the wire between that location and the headlight shell prior to installing the wire's connectors. cut a piece of wire long enough to reach from your passing lamps connector to your switch install-location.All rights reserved Page 12 of 25 . At this point you’ll want to be sure you have the power leads (wires) for both passing lamps terminating together near your switch install-location. right. Heat-shrink or tape exposed areas of the connectors as needed. MO USA. Fasten your wire segment to the other terminal of the switch. both of my passing lamp power wires terminate there. or a spade connector (if your toggle has spade terminals) to the other end. Next cover exposed areas with tape or heat-shrink as always. cut another piece of the same wire long enough to reach from the tap wire you made to your toggle switch install-location. Then. right. To do this. ©Randy Fox. as shown in the diagram. Fasten your wire segment to one terminal of the switch. Crimp or solder a female spade connector onto one end. Proceed to Finishing Your Installation. right.

©Randy Fox.Option 4: Lamps Toggled UP to Stay On. Crimp or solder a male spade connector onto one end. your switch has three terminals:  Power in from main power  Power in from high-beam  Power out (the center terminal) The Road Star uses a two-color. 2012 -. make a tap wire for the high-beam power. or DOWN to Go On/Off With the Dimmer If this is the option you chose. piece of the wire you will use as your HIGH BEAM tap wire. the bike uses a yellow wire as its high-beam power wire. Orange tap-wire to bike’s yellow wire. cut a 3 inch. Next. right. red/yellow. Locate those wires inside the headlight shell and splice/tap into them. See the blue wire in the diagram. To do this. Crimp or solder a female spade connector onto one end. piece of the wire you will use as your POWER tap wire. MO USA. right. striped wire as its 12 volt. | | | To make the first tap wire.by randysgym. Blue tap-wire to bike’s red/yellow wire. or so. use a splice or tap connector or solder the other end of your tap wires to convenient spots on the bike’s wiring. cut a 3 inch. Installing Passing Lamps w/Toggle -.All rights reserved Page 13 of 25 . always-on-whenthe-ignition-is-on. Also. or so. Next. See the orange wire in the diagram. power wire. St Louis.

right. | | Now. ©Randy Fox. See diagram. Installing Passing Lamps w/Toggle -. Then crimp or solder a male spade connector to the remaining free end. See diagram. To do this. Then. 2012 -. Fasten your wire segment to an end terminal of the switch. Now use a splice or tap connector or solder one of the leads to the other one. Then crimp or solder a ring-connector (assuming your toggle has screw terminals). cut a short piece of wire. Crimp or solder a male spade connector onto one end. you may want to route the wire between that location and the headlight shell prior to installing the wire's connectors. crimp or solder a ring-connector (assuming your toggle has screw terminals). Now make the corresponding wire segment for the toggle switch. make a corresponding wire segment for the toggle switch. Example: If your toggle switch will be in the left passing lamp shell then the leads for BOTH passing lamps must terminate to the rear of the left shell. See diagram. or a spade connector (if your toggle has spade terminals) to the other end.All rights reserved Page 14 of 25 . cut another piece of the same wire long enough to reach from your tap wire to your toggle switch install-location. leaving at least 3 inches of free-end length on one wire. or a spade connector (if your toggle has spade terminals) to the other end. MO USA. cut another piece of wire long enough to reach from your tap wire to your toggle switch install-location. Crimp or solder a female spade connector onto one end. See diagram. ideally the same color as the lamps wire. Fasten this wire to the center terminal of the switch. but do not plug the spade connectors together yet. | | At this point you’ll want to be sure you have the power leads (wires) for both passing lamps terminating together near your switch install-location. left. To do this. St Louis. as shown in the diagram. right. Since my toggle switch is in the headlight shell. To do this. both my passing lamp power wires terminate there. Tip: If your switch is going to be in one of the passing lamp shells.Now make the corresponding wire segment for the toggle switch.by randysgym. but don’t plug the spade connectors together yet. right.

follow the wiring instructions for Option 4. 2012 -. MO USA. Fasten your wire segment to the remaining terminal of the switch. Tip: If your switch is going to be in one of the passing lamp shells. The option above uses a 2-position toggle. See Page 2 or the box-note. you may want to route the wire between that location and the headlight shell prior to installing the wire's connectors. whereas this option uses a 3-position toggle -. Just be sure you purchase an On/Off/On toggle switch.the center position being. above. above. If you chose this option. ©Randy Fox. St Louis. but do not plug the spade connectors together yet. crimp or solder a ring-connector (assuming your toggle has screw terminals). Installing Passing Lamps w/Toggle -. Then. or a spade connector (if your toggle has spade terminals) to the other end.by randysgym. | | | | Option 5: 3-Way Switch Setup This option is wired exactly the same as Option 4.Crimp or solder a female spade connector onto one end.All rights reserved Page 15 of 25 . for details on purchasing switches. Always-Off. Proceed to Finishing Your Installation. at right. The only difference is in the toggle switch you use.

SPDT switch just by shorting the two sides together.All rights reserved Page 16 of 25 . ©Randy Fox. SPDT switches). Installing Passing Lamps w/Toggle -. Now you can use either of the upper terminals interchangeably and either of the lower terminals interchangeably. make a small wire with connectors on each end. See photo below. MO USA.by randysgym.Money Saving Tip: If you are using a 6-terminal. 2012 -. and fasten the other connector onto the switch’s right-center terminal. St Louis. DPDT switch (which I find to be cheaper than 3terminal. you can make it work like a 3-terminal. To do this. Then fasten one connector onto the switch’s left-center terminal.

the spade connectors shown in the photo were for an earlier toggle installation. that white Velcro strips were used to further dampen any rattling. Please ignore them. Caution: Be sure you're ready before turning the ignition switch on.by randysgym. Since your headlight is still removed you won’t be able to verify that it still works yet. Now screw the phillips screws back in. Do a final check and test to be sure all is well and you haven't forgotten anything. If it all checks out.  And. right. ©Randy Fox.All rights reserved Page 17 of 25 . See photo below. Then re-secure the headlight wiring restraints by bending them onto the harnesses. MO USA. plug the headlight lens back in to its connector and hook the bezel back onto the shell. any exposed points along the wires and at the connectors can shock you or short and blow a fuse. Finish whatever needs doing for the passing lamps kit. then you’re good to go. turn the ignition back off. Then just work the bezel into place until the screw holes in the bezel align with the mounting threads in the shell.  Also. you can now install it and plug your spade connectors together. 2012 -. Photo peculiarity explanation:  In the photo. St Louis. the garage door opener shown is not part of this project. but everything else should work without it. and then test your installation. reconnect the battery. wiring connectors were wrapped with soft cloth to reduce rattle while riding on rough roadways. Job well done I'm sure! Installing Passing Lamps w/Toggle -.  Note too.Finishing Up If you wired for a toggle switch. of course. When you energize the ignition.

models Since it's generally accepted that a lighting circuit should be limited to about 85% of its capacity. follow the instructions below to power your lamps via a separate.0 amps). you can ignore the rest of this appendix. you will not be able to easily revert back to the stock carb heater. Or here’s a creative solution via Joe Friday: Repurpose the 10amp. for 2003. dedicated wire from the battery. approximately: 63 watts (5. radio. MO USA.or if you have upgraded your stock carb to an aftermarket one. 10amps equates to 120watts.and assuming your lamps are 35 watts (the most common) then your total demand on the Headlight Circuit wiring will be as follows: 87% for 2004+ Road Stars 90% for 2003. taillight. -. It’s behind the bike’s left side-cover. If this is the case. this 15 amp circuit should not be asked to supply more than 12.7 amps (152 watts). if you do this.the Headlight Circuit. carb heater circuit.3 amps). Tip: The Yamaha passing lamp accessory usually comes with 35 watt bulbs. fog lamps. for 2004+ models 68 watts (5. Now double the wattage since there are two bulbs.Road Stars If you're OK with that.models Find the wattage of your passing lamps. Remember: To convert watts to amps divide the watts by 12. first locate the Heater Thermo Sensor. The Road Star uses a 12 volt battery. 2012 -. ©Randy Fox.7 amps). and a few dash lights -. but 25 watts up to 55 watts are common replacements. thumb-nail looking component closest to you as you remove the side- Installing Passing Lamps w/Toggle -. rated at 15 amps. This means you should limit all accessory add-on demand attached to this circuit to: 89 watts (7. and to convert amps to watts multiply the amps by 12. It’s the little. on a rubber mounted tab. Note: The twelve comes from voltage. If you ride only in warm weather -. etc. these lights continually draw the following. The bottom line is this: Assuming you have not tapped into the headlight circuit for other accessories -. for 2003. To go this route. When the ignition is on. however. you aren’t using the carb heater anyway. black. for 2004+ models 84 watts (7. It incorporates a fuse in the main fuse box.heated grips. But if you feel it would be prudent to add a separate circuit.All rights reserved Page 18 of 25 . and return to the main article.4 amps). then you do not need to run a separate wire to power your lamps. St Louis. Note.say above 50 degrees or so -. you could disconnect the carburetor’s heating wires and use them for powering your passing lamps.by randysgym.Appendix A -Running a Dedicated Power Wire from the Battery Do you even need this? Determining Your Need The Road Star has a wiring circuit dedicated to the headlight.

©Randy Fox. 12VDC. If the relay you get has only 4 terminals. you'll also need the following: 16 or 14 gauge. St Louis. if you're installing 14 gauge wire. You can use a 20 amp fuse for 14 gauge wire. Also. I’d also recommend you change the label in your fuse box. Use 14 gauge if you want to be able to safely run more than 150 watts on this wire.by randysgym. 2012 -. I recommend red or white. You may want the in-line fuse to be accessible behind the left-side cover. I splurged for solidstate. stranded copper wire. and fasten them together (solder or butt-connector). Relay Socket -. you will not need to wire a relay as shown below. Butt-Splice Connectors -. Tip: Solid-state relays may work extremely well. Then go back to the top of this article. be sure to get at least one 14 gauge spade-connector set (male/female).to fit the relay you purchase.and a 10amp or 20 amp fuse. Wiring Guidelines First decide where you want your new wire to be routed. The cheaper contact-points type relay should work well enough. Then you can cut the heater fitting off the carb end of the wires. just cut the two wires. Follow the instructions for the option you choose. Ring Connector -. except use your newly repurposed wire instead of the bike’s red/yellow striped power wire. They are available at most auto parts stores as well as amazon. Thanks again Joe. MO USA. Additional Spade Connectors.com and other automotive supply places. as there is usually a lot of empty space available there. plus three 16 gauge sets.You'll need a 12VDC SPDT relay. That means. but they tend to be an unnecessary added expense.All rights reserved Page 19 of 25 . They are available at most auto parts stores as well as amazon. you’ll need to splice on a length of wire long enough for your purpose. Get 6 or 8 feet. suitable for the size wire you use. Of course. It’s the brown/blue striped wire. or other type -. rated for 20amps or higher. Or you may consider placing the fuse inside the headlight shell. Reroute this wire toward the front of the bike.com and other automotive supply places. Use a 10amp fuse for 16 gauge wire and no other accessories attached to the circuit. make sure it has the tab marked as "87". In-Line Fuse Holder -. IMO. This is the wire to supply the main power for your lamps. like the other fuses. 4 or 5 pin. If you’re sure you won’t be using your carb heater in the future.4 sets. Installing Passing Lamps w/Toggle -. Note however. It's OK if the tab marked as "87a" is missing. If you're installing 16 gauge wire you can just get four 16 gauge sets. 12VDC. flexible.cover.large enough to fit the battery Relay -. and has two black wires going into it. unless you will be soldering your connections.5 or so. Additional Materials Needed In addition to the materials and instructions in the main part of this article.

by randysgym. Refer to the main instructions for details. The goose-neck harness is the soft. refer to the appropriate wiring diagram shown below instead of the diagram shown in the wiring sections of the main article. tap into the black wire from the headlight connector harness. Next.  If you have a 5-pin (tab) relay socket. Now crimp or solder a properly sized female spade connector to the headlight end of your new power wire. as desired. crimp or solder a male spade connector. stiff wire. black. Now. Tip:Use a long. past the steering head. 2012 -. feed the wire along the left side of the frame's backbone and through the wiring goose-neck harness. leaving enough free wire to be able to reach the positive battery post at one end and the passing lamp wiring at the other end. then connect this to the red/yellow wire or yellow wire from the bike's wiring. though. To do this. If you will have no such switch. do not attach anything to the wire-lead associated with the relay terminal marked as "87a". wiring tube that goes from the left. Just be sure it will reach from the connector on the end of your new power wire to the placement location for your relay.After disconnecting the battery. if your relay socket does not have integrated wire leads. Now splice the in-line fuse holder to your new wire.  To the wire-lead associated with the relay terminal marked as "85". and the removing the headlight lens/bezel assembly. cut a short piece of wire to use as your power-in wire for the relay. make and fasten short wire-leads for the remaining relay socket terminals. Depending on which wiring option you choose. ©Randy Fox. as follows:  To the wire-lead associated with the relay terminal marked as "87". This will connect to ground. Connect the other end of the wire to the proper wire-lead on the relay socket you purchased. The relay can be fastened to your headlight shell (or other area) with silicone adhesive. Cut the wire to proper length for your application. crimp or solder a female spade connector. This will connect with your passing lamp power connector. forward section of the frame's backbone. removing the fuel tank. To do this. and a great deal of time and patience. and into the headlight shell.All rights reserved Page 20 of 25 . or other method. Do not yet attach anything to the battery. It should be the one associated with the relay terminal marked as "30".  To the wire-lead associated with the relay terminal marked as "86". MO USA. crimp or solder a male spade connector. Crimp or solder a properly sized male spade connector to one end. run your new power wire between the battery's left-side area and the headlight shell. then crimp or solder a ring fitting for the battery terminal on the end nearest the battery. St Louis. This will connect with the connector from the output of your toggle switch. Then crimp or solder spade connectors to these wire-leads. refer to the appropriate wiring diagram shown below instead of the diagram shown in the wiring sections of the main article: Installing Passing Lamps w/Toggle -. Depending on which of the toggle wiring options you choose. to fish the new wire through the goose-neck harness. rubber.

St Louis. MO USA. ©Randy Fox.Option 1: Lamps Always Stay On -.No Toggle Option 2: Lamps Go On/Off With the Headlight Dimmer Installing Passing Lamps w/Toggle -.All rights reserved Page 21 of 25 .by randysgym. 2012 -.

return to Page 1 of this document and complete the rest of your wiring. MO USA. Installing Passing Lamps w/Toggle -.by randysgym. return to Page 1 of this document and complete the rest of your wiring. St Louis. Option 3: Lamps Turn On/Off With a Toggle Switch Now. ©Randy Fox. 2012 -.All rights reserved Page 22 of 25 .Now.

by randysgym. 2012 -. or DOWN to Go On/Off With the Dimmer Now. MO USA.All rights reserved Page 23 of 25 . ©Randy Fox.Option 4: Lamps Toggled UP to Stay On. St Louis. Installing Passing Lamps w/Toggle -. return to Page 1 of this document and complete the rest of your wiring.

©Randy Fox.by randysgym.Option 5: 3-Way Switch Setup Now. Installing Passing Lamps w/Toggle -. St Louis. 2012 -. MO USA.All rights reserved Page 24 of 25 . return to Page 1 of this document and complete the rest of your wiring.

My passing lamps kept burning out bulbs. This practice has worked in vehicles of all types for many decades.All rights reserved Page 25 of 25 . ©Randy Fox. Coincidence? Maybe. 2012 -. This assembly consists of two sets of greased bearings which may not offer ideal conductivity between the front-end and the rest of the bike. Suspecting it might be a poor grounding issue after I had thoroughly repacked my steering-head bearings with a non-conductive grease. However. MO USA. Maybe not. The only contact point between the bike's frame and the entire fork assembly is at the steering head. conducting power back to the battery's negative pole.Appendix B -. St Louis. I decided to replace my passing lamp bulbs with ones that featured an actual ground wire terminal. I believe there can be a problem with this for motorcycle lighting.by randysgym. Since then I’ve had no more burnt out bulbs. I believe this may be why the headlight has a dedicated ground wire. …I’m just sayin’… Installing Passing Lamps w/Toggle -.Possible Grounding Issues Most passing lamps have only one lead -. A ground wire is not considered necessary since the entire frame of the bike is designed to function as one big ground wire.the power (hot/live) wire.

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