I have soldered the regulators in place but you can just as easily use crimps to do the job.
Please look at this picture:
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
Slide some heat shrink over the leads
Take the regulator and citylight socket and twist the black/white output wire to the purple/yellow wire and solder together
Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal
Twist the regulator output black ground wire and the brown citylight harness wire togehter and solder
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
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
Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal
To help with the ground connection pull off the highbeam bulb harness
Twist the regulator black ground wire and the headlight housing brown ground wire together and solder
Pull the heat shrink over the solder connection and heat to seal. Or use some electrical tape to seal
You have just completed splicing in the regulator circuit. Insert the LED into the citylight socket and then insert into the headlight housing
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
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