How to properly wire a light bar?

**BigRed** · 07-20-2013, 04:47 PM

I bought an 08 Nomad a couple of days ago and the bike came with a light bar. It looks like it might be a Cobra bar. The bar is wired directly to the battery so it can only be turned on with a switch. I want to rewire it so that the lights come on when the bike starts but I still want to be able to turn the lights off with the switch.

Would it be OK to tap into the head light for power or am I risking blowing fuses, melting cables and possible issues with the ignition switch due to overload?

Thanks

Martin

recumbentbob · 07-20-2013, 05:07 PM

This: http://www.gadgetjq.com/wiredrivinglights.htm

**BigRed** · 07-20-2013, 05:54 PM

Thanks recumbentbob.

recumbentbob · 07-20-2013, 06:26 PM

I mounted my relay under the speedometer cover and drilled a hole in the side of the cover on the left towards the front and mounted a toggle switch.

**HwyRider** · 07-21-2013, 12:19 AM

To properly wire a light bar you should install a cheap aux. fuse panel somewhere on the bike that only comes on after the bike is started. They sell them at Auto Zone and usually hold 6 fuses. You can use an aux connection from the headlight if there is one as the trip wire. That way nothing that comes from that fuse panel like heated clothing, light bar, or stereo runs until the bike starts.

After the fuse panel is installed you just plug right in to it for anything that you want to add.

**HwyRider** · 07-21-2013, 12:40 AM

If you do put in aux fuse panel you will use a relay to power the panel.

Here are the connections that you would need to make.

1. Connect a wire from the positive battery terminal to the #30 connector of the relay.

2. Connect a wire from #87 lug of the relay to post that powers the aux fuse panel.

3. Connect the aux wire from the headlight to the #86 lug of the relay.

4. Connect the #85 lug of the relay to the ground of the battery.

That's all there is to adding the aux fuse panel.

Once that's in just plug the positive of any accessory in to the new fuse panel and connect the ground either to a ground wire that is already there or to the frame.

**ringadingh** · 07-21-2013, 01:02 AM

Check out our Tech boards, they have a how to as well as some other good info.

**HwyRider** · 07-21-2013, 01:15 AM

None of those tutorials is for adding an auxiliary fuse panel. Most people that add to their bikes need additional fused circuits. Instead of having a 20 amp fuse here and a 15 amp fuse there everything is put in to one location that is nice and tidy instead of having wires running everywhere and multiple lugs coming off the top of the battery.

If you still need multiple wires coming from the top of the battery you just use 1 ring connector and add 3 wires to it with a quick connect plug on the opposite ends. It's a pigtail for both the positive and negative. Along with an aux panel it gives you all of the connections that you could ever need.

**BigRed** · 07-21-2013, 03:37 PM

Thank you all very much. I was able to rewire the light bar using a relay switch. I also purchased a fuse panel but couldn't find a good spot to mount it so this step will have to wait for another day.

**HwyRider** · 07-21-2013, 06:35 PM

Quote:

Originally Posted by BigRed

Thank you all very much. I was able to rewire the light bar using a relay switch. I also purchased a fuse panel but couldn't find a good spot to mount it so this step will have to wait for another day.

Good winter project.

**tomm** · 07-22-2013, 10:07 AM

I mounted mine to the battery hold-down bracket. If you do that, just make sure to put a piece of insulating material under the panel. The relay that powers the switched circuits is triggered off the tail light, and is in the upper right corner of the battery compartment, looking at the picture.

Quote:

Originally Posted by BigRed

Thank you all very much. I was able to rewire the light bar using a relay switch. I also purchased a fuse panel but couldn't find a good spot to mount it so this step will have to wait for another day.

**BigRed** · 07-23-2013, 08:22 AM

Quote:

Originally Posted by tomm

I mounted mine to the battery hold-down bracket. If you do that, just make sure to put a piece of insulating material under the panel. The relay that powers the switched circuits is triggered off the tail light, and is in the upper right corner of the battery compartment, looking at the picture.

Nicely done. Thank you.

07-20-2013, 04:47 PM	#1
BigRed Join Date: Jul 2013 Location: Central Massachusetts Posts: 765	How to re-wire a light bar? I bought an 08 Nomad a couple of days ago and the bike came with a light bar. It looks like it might be a Cobra bar. The bar is wired directly to the battery so it can only be turned on with a switch. I want to rewire it so that the lights come on when the bike starts but I still want to be able to turn the lights off with the switch. Would it be OK to tap into the head light for power or am I risking blowing fuses, melting cables and possible issues with the ignition switch due to overload? Thanks Martin Login or Register to Remove Ads
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07-20-2013, 05:07 PM	#2
recumbentbob Sr. Member Join Date: Mar 2009 Location: Newburgh IN Posts: 3,404	This: http://www.gadgetjq.com/wiredrivinglights.htm __________________ VBA #01084 "A well regulated militia being necessary to the security of a free State, the right of the People to keep and bear arms shall not be infringed."
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07-20-2013, 06:26 PM	#4
recumbentbob Sr. Member Join Date: Mar 2009 Location: Newburgh IN Posts: 3,404	I mounted my relay under the speedometer cover and drilled a hole in the side of the cover on the left towards the front and mounted a toggle switch. __________________ VBA #01084 "A well regulated militia being necessary to the security of a free State, the right of the People to keep and bear arms shall not be infringed."
	0

07-21-2013, 12:19 AM	#5
HwyRider Join Date: Jun 2013 Location: South Shore, MA Posts: 4,629	To properly wire a light bar you should install a cheap aux. fuse panel somewhere on the bike that only comes on after the bike is started. They sell them at Auto Zone and usually hold 6 fuses. You can use an aux connection from the headlight if there is one as the trip wire. That way nothing that comes from that fuse panel like heated clothing, light bar, or stereo runs until the bike starts. After the fuse panel is installed you just plug right in to it for anything that you want to add. Login or Register to Remove Ads
	0

07-21-2013, 01:02 AM	#7
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	Check out our Tech boards, they have a how to as well as some other good info. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
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07-20-2013, 05:54 PM	#3
BigRed Join Date: Jul 2013 Location: Central Massachusetts Posts: 765	Thanks recumbentbob. Last edited by BigRed; 07-20-2013 at 06:11 PM.
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07-21-2013, 12:40 AM	#6
HwyRider Join Date: Jun 2013 Location: South Shore, MA Posts: 4,629	If you do put in aux fuse panel you will use a relay to power the panel. Here are the connections that you would need to make. 1. Connect a wire from the positive battery terminal to the #30 connector of the relay. 2. Connect a wire from #87 lug of the relay to post that powers the aux fuse panel. 3. Connect the aux wire from the headlight to the #86 lug of the relay. 4. Connect the #85 lug of the relay to the ground of the battery. That's all there is to adding the aux fuse panel. Once that's in just plug the positive of any accessory in to the new fuse panel and connect the ground either to a ground wire that is already there or to the frame.
	0

07-21-2013, 01:15 AM	#8
HwyRider Join Date: Jun 2013 Location: South Shore, MA Posts: 4,629	None of those tutorials is for adding an auxiliary fuse panel. Most people that add to their bikes need additional fused circuits. Instead of having a 20 amp fuse here and a 15 amp fuse there everything is put in to one location that is nice and tidy instead of having wires running everywhere and multiple lugs coming off the top of the battery. If you still need multiple wires coming from the top of the battery you just use 1 ring connector and add 3 wires to it with a quick connect plug on the opposite ends. It's a pigtail for both the positive and negative. Along with an aux panel it gives you all of the connections that you could ever need.
	0

07-21-2013, 03:37 PM	#9
BigRed Join Date: Jul 2013 Location: Central Massachusetts Posts: 765	Thank you all very much. I was able to rewire the light bar using a relay switch. I also purchased a fuse panel but couldn't find a good spot to mount it so this step will have to wait for another day.
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