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Old 02-13-2011, 04:06 PM
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Instructions how to do a relay 3 headlight mod complete with video

Just finished doing my relay type 3 headlight mod and thought I would share.

Here's what you will need:
Single Pole Double Throw Relay 20 amps or higher, 4 or 5 pin.
Either 4 female adapters and wire or a relay socket (recommended).

I got both of these on amazon.com for $7.44 shipped to my door from ipodcarparts, I am sure you can pick them up at your local auto parts store as well.

Amazon.com: 12 VDC Waterproof Relay SPDT 30/40A with Metal Bracket: Electronics Amazon.com: 12 VDC Waterproof Relay SPDT 30/40A with Metal Bracket: Electronics

You will also need a sharp knife, wire stripping tool, screwdriver, liquid tape (got mine at home depot for $5), electrical tape, and dielectric grease (Auto Zone).

Steps:
Remove battery, remove pod cover, unplug speedo and gauges, cut all cable ties to give some room, find switch bundle by following it from the switch, carefully cut into it and find the green and yellow wires.

Use the orange and white and brown wires from the 12 volt cigarette outlet for power and ground. Here's how the relay wiring goes:

#30 will be the feed from the battery or the orange wire with the white tracer
#85 will be the ground brown
#86 will be the wire from the high beams yellow
#87 will be the wire to the low beams green
If you get a 5 pin there will be a 87a, don't worry about it, just "dead end" it.


lowbeamlight-1.jpg

You will need to strip off a little of each wire to do a tap solder on each of the 4 wires. Make sure you use dielectric grease or liquid tape at all soldered connections to prevent corrosion, I added a wrap of electrical tape as well for good measure. I mounted the relay to the steering column using double side foam tape and a wrap with electrical tape. Don't forget to put a little dielectric grease on the pins on the relay to prevent corrosion inside the socket.

Here's my video to help if you need it:

I want to let all of you know that I am an amature and certainly do not do this for a living, so keep your negative comments to yourself please. My goal is to help anyone who's worse than I am at this kind of stuff.

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Last edited by bgirard420; 03-21-2011 at 03:03 PM.
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Old 02-13-2011, 04:16 PM
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Quote:
Originally Posted by bgirard420 View Post
Just finished doing my relay type 3 headlight mod and thought I would share.

Here's what you will need:
Single Pole Double Throw Relay 20 amps or higher, 4 or 5 pin.
Either 4 female adapters and wire or a relay socket (recommended).

I got both of these on amazon.com for $7.44 shipped to my door from ipodcarparts, I am sure you can pick them up at your local auto parts store as well.

Amazon.com: 12 VDC Waterproof Relay SPDT 30/40A with Metal Bracket: Electronics

You will also need a sharp knife, wire stripping tool, screwdriver, liquid tape (got mine at home depot for $5), and electrical tape.

Steps:
Remove battery, remove pod cover, unplug speedo and gauges, cut all cable ties to give some room, find switch bundle by following it from the switch, carefully cut into it and find the green and yellow wires.

Use the orange and white and brown wires from the 12 volt cigarette outlet for power and ground. Here's how the relay wiring goes:

#30 will be the feed from the battery or the orange wire with the white tracer
#85 will be the ground brown
#86 will be the wire from the high beams yellow
#87 will be the wire to the low beams green
If you get a 5 pin there will be a 87a, don't worry about it, just "dead end" it.


Attachment 2105

You will need to strip off a little of each wire to do a tap solder on each of the 4 wires. Make sure you use dielectric grease or liquid tape at all soldered connections to prevent corrosion, I added a wrap of electrical tape as well for good measure. I mounted the relay to the steering column using double side foam tape and a wrap with electrical tape.

Here's my video to help if you need it: YouTube - Polaris Sportsman 500 H.O. 3 Headlight Modification

I want to let all of you know that I am an amature and certainly do not do this for a living, so keep your negative comments to yourself please. My goal is to help anyone who's worse than I am at his kind of stuff.


Any chance you could kill the music?? To hard to hear you over it. But I look forward to getting mine, will be watching your video as I install it.
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Old 02-13-2011, 04:26 PM
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LOL!! I added the music because I sound like an idiot! If I get enough requests to turn the music off maybe I will edit it.
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Old 02-13-2011, 04:41 PM
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nice video, but you gotta kill the music. Your voice sounds fine, but you are used to hearing it through bone conduction and not air conduction. We all sound far worse than we think we do when we hear ourselves through speakers.

Thanks for the effort you put in on this.
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Old 02-13-2011, 05:16 PM
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Originally Posted by fourbuyfour View Post
nice video, but you gotta kill the music. Your voice sounds fine, but you are used to hearing it through bone conduction and not air conduction. We all sound far worse than we think we do when we hear ourselves through speakers.

Thanks for the effort you put in on this.
Alright, do to popular demand I edited and the video and now it is just me and my bad boston accent
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Old 03-15-2011, 09:16 AM
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I just ordered the relay and the socket, VERY nice video man. Thanks for the upload!
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Old 03-15-2011, 09:43 AM
bgirard420's Avatar
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I just ordered the relay and the socket, VERY nice video man. Thanks for the upload!
Thanks, and good luck! I got a little lazy at the end and just started taking stills, but the point comes across. I had never done a "tap" type of solder before this project, makes sense to split the wire down the middle and wrap from both sides. This thing is never coming apart. The way I figure is that I don't plan on submerging the pod, but if it ever happens I know my connections will survive!
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Old 03-15-2011, 11:03 AM
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I need to go hunt down liquid tape and a soldering iron...
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Old 03-21-2011, 11:26 AM
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I knocked this out in about 15 minutes on sunday. The relay and almost all the wires were the same on my 2008 800. Thanks again for the vid Mr. Girard, made this mod a breeze and is awesome with my HID's. I feel sorry for the poor bastard riding in front of me
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Old 03-21-2011, 12:34 PM
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Quote:
Originally Posted by bgirard420 View Post
I want to let all of you know that I am an amature and certainly do not do this for a living, so keep your negative comments to yourself please. My goal is to help anyone who's worse than I am at his kind of stuff.

I agree with keeping the negatives out unless it's in regard to possibly
a safety factor. Visuals always seem to help out more then words can
say for the most part. Great job
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