Wiring in accessories the correct way.

[sickpup]

So you want to add a load of electrical accessories to your bike and don't know how so here's a guide.

This is based around the system I have fitted to my ER6F work bike but it is transferable to all other bikes.

Parts required.

1. 6 way Fuse box.
2. Standard 4 pin relay rated at 30+amps
3. 2 metres of red cable able to handle 20 amps.
4 1 metre of black cable able to handle 20 amps.
5. Various sizes of heat shrink tubing
6. Female Lucar terminals and insulation.
7. Female bullet terminals and insulation.
8. Male bullet terminals and insulation.
9. Double crimp ring terminal 6.4mm hole.
10. Inline fuse holder.
11. 6 way stationary blade.
12. M4x10 Allen bolts.
13. M4 Lock nuts.
14. M4 washers.

First we need to find somewhere to mount the relay. On a modern bike with lights always on I recommend using the live feed from the rear light but on an older bike I would use the live to the rear brake light switch so where you fit the relay is dependant on this and being in close proximity to the battery live terminal.

On my ER6F I fitted the relay under the rear left side panel. Conveniently there is a mount point just above the seat lock.

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0330.jpg

Now we need a live and an earth point for the magnet side of the relay. On the ER6 I used the rear light live. I removed the terminals from the 3 way plug then removed 8mm of insulation from the live wire and soldered an separate 6 inches of red wire to it. Cover the soldered joint with heat shrink, shrink it and pop the terminals back into the plug. At the end of the red cable add a female bullet terminal with insulation. Use a female as this wire is live and when disconnected the insulation stops the terminal touching any earth. You now need another piece of red wire with a male bullet and insulation on one end and a female lucar terminal and insulation on the other. This connects between your new live and the relay post marked '85'.
For the return from the relay you will a piece of black wire with a female lucar and insulation on one end attached to post '86' on the relay and a ring connector insulated with heat shrink to go on the other which is attached to an earth point.

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0331.jpg

As you can see in this picture I have wrapped the live and negative to the relay in heat shrink and they go to pretty much the same place. The negative is attached to an earth point, in this case the 10mm headed bolt under the bullet connector.

Now we need a live from the battery to the Switch side of the relay. This is simply a piece or red wire with a ring terminal on one end attached to the battery, an inline fuse holder with a 15amp fuse in the middle and a lucar female terminal and insulation

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0352.jpg

connected to post '30' on the relay.

I tend to place the secondary fuse box at the front of the bike under a fairing panel. As most accessories are placed at the front of the bike so you can reach them when sat on the bike. This also has the advantage of only needing one live from the relay to the fuse box so cutting down on wiring. You need to place the fuse box in such a position that it is protected from the elements but is accessible in the case of a blown fuse. On the ER6 the best place was under the fairing attached to the inner fairing by M4 bolts just ahead of the radiator exhaust cut out.

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0334.jpg

The stationary blade that we will use as an earth point is fitted just above the fuse box. The yellow arrow points to it.

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0351-1.jpg

The stationary blade needs attaching to an earth point and all negative leads from accessories get attached to the stationary blade. Although I used a piece of wire with a female lucar on one end and a ring on the other it should really be ring to ring or you use one on the stationary blade points that could be used for an accessory.

Now the last bit. run a red live wire from post '87' on the relay using a female lucar and insulation to the live side of the fuse box. If you use the same type of fuse box I did you need to run a live to each fuse.

which I did with loops of wire into Female lucar connections. As you have fused before the relay and in the fuse box there is no need for an additional fuse on the live wire. if you have attached the fuse box to a removable bit of body work it is convenient to add a bullet connector into the line to facilitate removal.

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0351.jpg

Remember all live wires should use female bullets as the insulation on these is all enclosing so stopping any short circuits if disconnected.

So there you go 6 individually fused live points and earths to connect all the extras you want and it all turns off with the ignition so no dead battery.

On my bike I run heated grips and two cigarette lighter sockets off the fuse box.

https://i945.photobucket.com/albums/ad297/750RK/ER6%20Electrics/DSCF0336.jpg

[lihp]

Just posting to say I am impressed pics still work after more than 3 years.
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covent.gardens: lihp is my most favourite member ever

[c_dug]

It's a thread well worthy of a bump too , there should be a sticky thread with links to this sort of how to guide and maybe product reviews too so they're not all lost deep in the mix of nodding threads and welded sprockets.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[Fisty]

Bump for justice, because many folks will be fitting heated grips in the cold weather.
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Quietly and consistently taking the piss.
TL1000R | Hayabusa | ZXR400 | TL1000S | Bandit 400 V
Fatter and faster than Fret

[UncleFester]

Topical - used this guide last night - thanks very much!
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2017 Z1000SX

[phatstorage]

Still looking for those miximum fuses