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Message started by Ed_L. on 07/29/06 at 16:35:04

Title: Installing a Headlight Relay
Post by Ed_L. on 07/29/06 at 16:35:04

There has been some intrest shown in how to reduce the load on the battery while starting a Savage. One way is to install a relay that shuts off the headlight while the starter is cranking the engine. Seems that Suzuki has just added this feature to the 2007 model. I added a cutoff relay two years ago to my '02 and here is how I did it.
First you need a basic understanding of how relays work, they are just electrical switches (contacts) controlled by an electromagnet. They come with different contact configurations that can have the contacts open (switch off) or closed (switch on) when power is applied to the control electromagnet. The contacts are also rated according to how much power they can handle.
For the mod I used a mico-relay purchased at Radio Shack. I used a double pole (DP) double throw (DT) relay with the contacts rated at 15 amps with 12 volt DC control voltage. The double pole (DP) means that you can run both low and high beams thru the relay. The Double throw (DT) means that the relay has contacts that are closed (switch on) with no power as well as contacts that are open (switch off) with no power. The contacts that are wired into the headlight are the ones that are closed with no power. These are marked on the relay as the NC (normally closed) contacts which will open (switch off) and turn off the headlight when the control power is applied to the relay. It sounds complicated but it really isn't, a relay is just a switch that can turn things on or off depending on which contacts are used, NC (on with no power) or NO, normally open (off with no power).
The control voltage needs to provide power to the relay only during starting. The easiest spot to hook up a wire for this is the terminal on the starting solinoid that the wire going to the starter is attached to. This terminal only gets power when starting the bike and can be found under the rubber boot under the seat.
Here's a picture of the solinoid
http://www.bikepics.com/pictures/644041/
I ran the wire, 14 gauge, along the left frame rail and just slipped it under the tank and into the back of the headlight. Although I never got around to installing an in line fuze I would recomend it, maybe something around a 5 amp.
Here are two other pictures of the relay being installed
http://www.bikepics.com/pictures/644049/
http://www.bikepics.com/pictures/644056/
I put the relay in the headlight housing which turned out to be a tight fit mainly because of the extra room needed for the spade connectors. If I had to do this again I would just solder the wires onto the relay, a lot easier than fooling around with spade connectors and short wires. The other option is a toggle switch, just don't forget to turn it back on.

Title: Re: Installing a Headlight Relay
Post by 911radioman on 07/29/06 at 17:58:35

Thanks for posting this, Ed! Not trying to be overly taxing on your time, but do you happen to know what the Radio Shack catalog number was for that relay?

Also, I'm wondering if Suzuki has schematic/parts breakdowns that shows where they placed the relay at to achieve this?

Title: Re: Installing a Headlight Relay
Post by Ed_L. on 07/29/06 at 19:29:28

Sorry, don't have the part number, it was two years ago when I did the mod. Next time I'm in one of thier stores I'll try to get it. I'll guess that Suzuki put the relay somewhere under the seat and spliced into the main harness instead of trying to squeeze it into the headlight. I would of installed it under the seat but don't like the idea of cutting into the main harness. Looks like Clymer will need to update the wiring diagrams whenever they get around to it.

Title: Re: Installing a Headlight Relay
Post by vroom1776 on 07/31/06 at 10:01:49

Ed,

Nice work!

On the same note, one could install a switch to turn the headlight off manually, as in this thread: Light Switch Mod (http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;num=1130526053;start=0#0)

Basically I got a 6 Amp SPDT swithc from radio shack and spliced it in. This switch allows me to go Hi/Off/Low. Ground to the center pin, Hi to one side pin, Low to the other.

One could also get a simple on/off (i.e. SPST) switch, splice it in, and still use the handle bar switches, but I'm not sure where to put it w/o looking a the wiring diagram again. Uh, let's see, I THINK you could wire both Hi/Low through the same SPST switch. When it's in the Off position, it would jsut "open" the circuit so no current would flow to either beam.

V

Title: Re: Installing a Headlight Relay
Post by Ed_L. on 07/31/06 at 15:25:35

Splicing in a toggle switch would be the easiest, cheapest and quickest way to go for a headlight cutoff setup, no doubt about it. I tend to over engineer most projects that way I'm really surprised when they work ;D.

Title: Re: Installing a Headlight Relay
Post by SAMM on 07/31/06 at 21:32:27

I opened up the headlamp and cut the high beam wire ( I never use high beam ) so the headlamp could be shut off with the switch in the high beam position... Works great !! ;D

Title: Re: Installing a Headlight Relay
Post by SeeAPierce on 08/08/06 at 08:46:38

This feature is stock on the '06 as well...

Title: Re: Installing a Headlight Relay
Post by 911radioman on 08/08/06 at 11:28:55

Well, I just came from Radio Shack. Not good news on the relay front. Seems they don't make a 15A/12V DPDT relay. The biggest they had was a 10A, and I was afraid to try that.

Anybody got any ideas on relays?

Title: Re: Installing a Headlight Relay
Post by vroom1776 on 08/08/06 at 16:50:57

The head light should not be drawing 15A. A 10 amp will do fine. As above, I am using a 6A switch to control my headlight.

P = I*V

P = 60 W (HL bulb)
V = 12 V (battery)
=> I = 5 A

even w/ a 100 W bulb,

100/12 = 8.33 A

Title: Re: Installing a Headlight Relay
Post by Guido on 08/19/06 at 19:33:36

My 05 has the cut-off for starting.

Title: Re: Installing a Headlight Relay
Post by smokey02 on 08/27/06 at 08:13:25

My parts guy at work got me some samples of these.
NEC EQ1-31000S SPDT 30A 12V
I plan to use one for high/low beam and one for no headlight on start. They are small, sealed, about 3/4 x 3/4 x 1/2 inch. Tomorrow I'll find out where he got them.

http://p1.bikepics.com/2006%5C08%5C27%5Cbikepics-665859-full.jpg
http://p1.bikepics.com/2006%5C08%5C27%5Cbikepics-665861-800.jpg

Title: Re: Installing a Headlight Relay
Post by smokey02 on 08/28/06 at 20:47:36

mouser.com is where they come from
on page 1377
part no EQ1-31000S
$1.68 each

Title: Re: Installing a Headlight Relay
Post by Ed_L. on 09/08/06 at 17:34:55

Hey those are nice, shouldn't have any problem rigging them up.

Title: Re: Installing a Headlight Relay
Post by ratdog472 on 09/09/06 at 12:32:24

Ratshack 10A DPDT relay:

http://www.radioshack.com/product/index.jsp?productId=2049722&cp=&fbn=Type%2FDPDT&f=PAD%2FProduct+Type%2FDPDT&fbc=1&kw=relay+dpdt&parentPage=search

$8.49 for those who don't want to wait.

Title: Re: Installing a Headlight Relay
Post by Savage_Rob on 10/13/06 at 08:17:34

Guys,

Let's take the questions and discussion to the RSD forum. This forum is supposed to be for reference/how-to listings. Once there's something relevant to add to this thread, then it goes here.

Thanks.

Title: Re: Installing a Headlight Relay
Post by batman on 05/19/16 at 22:22:34

three wires go to your head light high beam +,low beam+, ground , splice a toggle switch into the ground wire bingo ! kills both high and low beam. mount it were you like.(it has to have a ground, your headlight shell is plastic)I believe it will be the wire on the center connection ,grounds on our bikes are usually black in color.

Title: Re: Installing a Headlight Relay
Post by Kris01 on 05/31/16 at 20:46:39

2007-2009:
B/W is ground. This may apply to other years as well.