MC Hammered

Here is a writeup on how to install the voltage regulator for the citylight LED conversion.

I have soldered the regulators in place but you can just as easily use crimps to do the job.

Please look at this picture:

<img src="http://podi.ca/regulator%20install/IMG_2327.JPG">

The top item is the cut off citylight harness with enough wire to splice in the circuit board.

Below the citylight harness is the regulator circuit.

The wires on the LEFT hand side behind the regulator (black square thing) are the INPUT wires.

The wires on the RIGHT hand side closest the baby blue resistor are the OUTPUT wires which connect to the citylight harness.

The most important things to remember are as follows:

- Black wires in the middle of the regulator circuit baord are ground

- Black wires with a white stripe are positive wires

- Brown wire on citylight harness is ground

- Purple with yellow stripe is the positive wire

DO NOT cross connect the input wires to the regulator circuit or you will burn out the regulator.

Black goes to brown... Black/White goes to Purple/Yellow. That's it!

So now lets go wire it all up...

First cut off the citylight harness with about 1.5" of wire left pigtailling off the harness

<img src="http://podi.ca/regulator%20install/IMG_2306.JPG">

Slide some heat shrink over the leads

<img src="http://podi.ca/regulator%20install/IMG_2307.JPG">

Take the regulator and citylight socket and twist the black/white output wire to the purple/yellow wire and solder together

<img src="http://podi.ca/regulator%20install/IMG_2328.JPG">

Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal

<img src="http://podi.ca/regulator%20install/IMG_2329.JPG">

Twist the regulator output black ground wire and the brown citylight harness wire togehter and solder

<img src="http://podi.ca/regulator%20install/IMG_2333.JPG">

Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal.

When you complete the output connection to the citylight harness this is what it should look like

<img src="http://podi.ca/regulator%20install/IMG_2303.JPG">

The input side connections are a little harder due to the amount of workspace so be careful!

Twist the regulator black/white input wire and the headlight housing purple/yellow wire together and solder

<img src="http://podi.ca/regulator%20install/IMG_2335.JPG">

Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal

<img src="http://podi.ca/regulator%20install/IMG_2336.JPG">

To help with the ground connection pull off the highbeam bulb harness

<img src="http://podi.ca/regulator%20install/IMG_2334.JPG">

Twist the regulator black ground wire and the headlight housing brown ground wire together and solder

<img src="http://podi.ca/regulator%20install/IMG_2337.JPG">

Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal

<img src="http://podi.ca/regulator%20install/IMG_2338.JPG">

You have just completed splicing in the regulator circuit. Insert the LED into the citylight socket and then insert into the headlight housing

<img src="http://podi.ca/regulator%20install/IMG_2305.JPG">

Turn on your headlight switch and then gently press the headlight harness into the back of the headlight. If everything is connected up properly the LED will illuminate.

Now repeat all above steps for the other headlight housing.

When completed both headlights will look like this with the citylights on

<img src="http://podi.ca/regulator%20install/IMG_1770.JPG">

Big D

for that.

MADD2.0T

That resistor looks like it is going to melt thru the wires leading to the citylight Just a heads up

PimpluxA4

thanks!

MC Hammered

And I also adjusted the positioning after taking that picture.