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| Installation instructions must be followed exactly and all steps completed prior to applying power or the unit will be damaged. Connecting the unit backwards will damage the unit. |
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If you need installation support (please see note*) 2. The link is used for ordering wiring diagrams. Note |
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Problem
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| We are using
this particular example to reveal what takes place more times
than not. We are providing this exchange so you can see the results of an incorrect installation. The customer bought a closeout model headlight modulator and returned it because he said it didn't work. We didn't find anything wrong and agreed to give him credit toward one of the newer models. He insisted that he knew what he was doing and did everything correctly. Customer: I installed the replacement modulator tonight and it doesn't work either. It actually blows the motorcycle fuse when switched On. Prior to installing the unit I took great pains to insure it was connected properly and used a multi meter to confirm each wire of my circuit plug. I also tried it on my bench power supply and it makes the supply go into overload protection. I'm an electrical engineer so I understand electronics. Can I send this thing back for a refund? As much as I want it to work, I'm tired of messing with it. Us: Sorry but that won't be possible. I can tell you without any doubt that you've connected the unit backwards. If it's blowing the fuse or putting a power supply in overload then you've blown the suppression diode in the circuit which prevents total destruction. Note: We sent him a photo of the component in question and suggested he open the case and check the diode with an ohmmeter. Customer: Thanks for the picture and explanation. I took the box apart and checked the diode. Not only was it shorted, but the top was blown off. I replaced the diode and hooked it up to my bench power supply. It worked fine. Before I hook it to the bike I'm going to go through the wiring again and double check things. |
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Be sure to check your battery, especially after all the testing on an installation. A customer called explaining he was sure everything was connected properly but the unit he was installing would not work properly. We suggested he remove the unit and perform a bench test which resulted in proper operation. He was really puzzled. We suggested that the battery should be checked as these small batteries can be depleted quickly when the electrical system and all the lights are on while installing an electrical device. He called later advising that he'd charged the battery and now everything works as advertised. |
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WARNING ABOUT JUMP STARTING A customer recently had a dead battery after leaving the key on overnight and tried to start the motorcycle with a battery charger, rather than jumping from a battery, which caused a high voltage spike that damaged one of our brake light devices. Always charge the battery for a couple of hours and then disconnect the charger before cranking the engine which creates a very high load demand. It's best to jump with a battery that's not being charged at the time, either by portable charger or a running automobile engine. Voltage spikes over 18 volts can damage radios, GPS units and other electronics. Our units contain over voltage protection up to 18 volts without damage. Above that our protection component will short to protect the circuit board. |
| Question 1:
After installation the unit would not modulate. The bike was
still in the garage under florescent lighting. Answer: The IR detector is not triggered by florescent light. It requires either sufficient sunlight or an incandescent bulb. |
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| Question 2: After installation the unit would not modulate.
A flashlight was used to trigger the IR detector. Answer: The light was not left on the detector long enough. There is a one second delay in the programming. |
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| Question 3: H7
model - The standard connectors on the wires do not fit
the spades on my headlight plug. Answer: On some models the bulbs are mounted in a special socket and the spades on this socket are wider than the standard 1/4" that's on our wires. It is necessary to cut the wires to the bulbs and install mating crimp connectors on the wires that connect to the modulator. |
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| Question 4: After
installation the unit would not modulate correctly or stop modulating. The
flash rate was very slow, about 1.5 seconds on and 1.5 seconds
off. The unit was returned for inspection and found to function
properly. Answer: The customer incorrectly attached the programming wire to a +12 volt source. The unit was in constant programming mode. |
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| Question 5: What is the Red wire for that's attached to the modulator and where is it connected. Answer: This is the programming wire. It's connected only if you want to change the factory default setting for the light detector delay time. If no change is desired then ignore the wire. If you want to make a change then follow the procedures shown in the programming table on the instruction sheet. |
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| Question 6: Does the headlight modulator work only during the daytime and not at night? Answer: The headlight will modulate only during the daytime when the high beam is selected. The bulb doesn't modulate at night under normal circumstances. |
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| TIPS - | |
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If the connectors show signs of heat damage it's due to electrical resistance caused by improper mating of the connectors. The spade in the male connector, if not centered properly, can slide by the edge of the metal receptacle in the female connector rather than fitting inside. This limits the current flow to a lesser area and thus the increase in resistance. |
| Question:
How do I bench test the modulator Unit? Answer: Connect the Blue output wire to a 12 volt test bulb (even a test light is OK). Attach the Green ground wire to battery negative first and then the Blue input (spaded) lead to the positive post. The input wires are always in the larger bundle of wires. The test light should illuminate. Shine a flashlight on the light detector to confirm the light modulates. Remember that there is usually a one second delay before modulating and a four second delay after removing the light from the detector lens. |
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 Always use a test light when checking circuits. |
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