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AC relay to run hi watt head light wiring?

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90gst_sean

15+ Year Contributor
566
10
Apr 9, 2006
Seattle, Washington
Last year I made a heavy gage wire loom for my Hella 80/100w h4 bulbs and install it in my gst with dedicated relays run off the oem head light power. Last month I swapped every thing to my GSX and I'm having issues with the light turning on at odd times. At the time of modification, I failed to realise the stock lights run 2 ground 1 power (not 2 power 1 ground); I will fix this as it may be a reason for the odd behavior.

The wiring problem I can handle on my own, what I'm wondering is; can I utilize the stock AC relay's and fuse box (I removed AC) to control my head lights and have a clean easily accessible modification.

I've yet to really think this hole thing through. I may wire in power for rally lights off a three position toggle that can be on / off / on with high beams. I realize that will likely need their own relay, as the ac system looks to only have 2 relays handy. I plan to redo my old wiring loom done last year. I failed to use quality wire in its construction and the difference in wire resistance is causing a difference in head light intensity from left to right.

I thought I'd get some opinions before starting.

- What amperage are the oem ac relays rated for?

- Can I just unplug the old ac wiring from under the "engine bay AC box" with out affecting any thing other that AC control already inactive?
 
I think the AC Relay would more than handle that load, if I recall correctly they are same as the Fan Relays - I did something similar to what you;ve done on my Mark VIII but bought an aftermarket Relay Harness Kit - Using the Relays as remote switches for handling high current - You wire the relay to the battery at one end, the light at the other end, and use the original headlight wires to trigger the relay(s) - You may want to look at the ready made relay harness kits from a place like Autodynamic.com - Auto Parts & Accessories Euro Lights Performance Import Domestic
 
I've yet to really think this hole thing through. I may wire in power for rally lights off a three position toggle that can be on / off / on with high beams.
I can show you how to properly wire rally lights like these with correct toggle switches. PM me with an email address that accepts attachments.
 

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As it sits, I have two relays running hi beam and low bean triggered off the stock head light power. The relays are sitting in a rubber tupperware container that must have condensation grounding my lights on all the time. When every thing was installed in the GST, I had the relay mounted above the driver side motor mount, and they stayed dry. Now that I have them in the GSX, with the relay stuffed down under the pass. head light I'm getting problems. This all started after lots of rain and a drive through car wash.
... makes sense to me, until I take a look any way.
 
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