Diagram, pictures and instruction provided by JSsDS (created 9/2/04)
Instructions
1. Use a sealed 15 amp fuse holder and connect one end to the battery connection on the starter solenoid using a 5/16" ring terminal. Wire length between the fuse and solenoid should be no more then 4". Connect a 14 gauge (RED) wire to the other side of the fuse and rout it with the existing harness up to the key switch/tach counsel area. This is where the relay will be located and a convenient place to locate all the necessary wires. NOTE: Pull the fuse until assembly is complete to prevent shorting the wire. While routing the wire, do not allow it to make contact with metal surfaces.
2. Connect the other end of the previously mentioned 14ga (battery) wire to the #30 terminal of the relay using a female spade connector.
3. Using a 3M brand inline connector, attach a wire (supplied by you) to the Blue high beam wire found at the end of the light switch harness - in this area. Attach the other end to the relay #86 terminal.
4. Attach a wire to the #85 terminal using a female spade connector. This wire will attach to a chassis ground later in the installation.
5. If installing two new lights take one wire from each new light and crimp them together in one end of a butt splice. (quick disconnect terminal instead of butt splices are preferred here so that you can remove the lights without having to cut the wires) Do the same with the other two light wires.
6. Crimp a wire to the other end of one butt spice (or quick disconnect). Attach the other end of the wire to the 87 terminal of the relay. NOTE: Quartz type lights are not polarity sensitive so it does not matter which wire is positive or negative.
7. Crimp a (BLACK) wire to the other butt splice (or quick disconnect) and attach it to a chassis ground along with the wire from the relay #85 terminal. A good chassis ground will be a bolt that retains a metal object to the frame. I used the front gas tank cover mounting bolt due to its close proximity to the relay's location. Use a ring terminal of the appropriate size to make the connection.
8. Use plenty of zip-ties to secure the wires, relay and fuse to prevent damage from the vibration that the massive power of the mighty DS produces. Do not mount the relay rigid to the frame as the vibration will eventually break it too. I just zip-tied it loosely to the frame. Be sure to point the terminals downward to prevent water from getting into the relay.
This arrangement, if installed correctly, will power up to 150 watts out of the #87 relay terminal without effecting the other circuits in the DS's electrical system. If more power is needed simply install a larger fuse holder. You are only limited by the 260 watt (20amps) output available from the charging system. All parts are available at your local auto parts store.
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