In the spirit of the DIY types ( and since an off the shelf harness wont work ) i figured id post up a DIY harness ....
the main reason off the shelf harnesses wont work is the samurai uses a constant hot, and switched grounds for headlights. this is the oposite of how its normaly done.
here is the headlight diagram taken from the 88 service man.
@ the headlight
w/bl & w/r are the comon hot
red is high - go's back thru switch to ground
red/white is low - go's back thru switch to ground
here is how the typical 6024 ( 7" round headlight) is wired...
and here is a typical wireing diagram for a relay harness...
so, on to the changes to adapt it to a sami....
on relay:
#86 will need to be hot. you can piggy back from term #30, or the w/bl or w/r wire from factory harness ( depends on what side you connect to).
from factory harness to relay:
red factory wire is neg high beam trigger, connects to #85 in diagram on relay 3
red/white wire is neg low beam trigger, connects to #85 in diagram on relay 1
my zuk has had awefull lighting since i got it. i tested the voltage the other day. with the factory harness disconnected from the lights so there was no draw, i only had 11.7v available. thats a 3volt drop with no load!
( 14.8v @ batt when running ) voltage droped below 9v when pluged in. no wonder i couldnt see at night! :shaking: so today i will go source relays , pigtails etc. i plan to make it plug n play so no cutting of a factory harness would be required.
i shuld be able to do some before/after beam shots etc.
the main reason off the shelf harnesses wont work is the samurai uses a constant hot, and switched grounds for headlights. this is the oposite of how its normaly done.
here is the headlight diagram taken from the 88 service man.
@ the headlight
w/bl & w/r are the comon hot
red is high - go's back thru switch to ground
red/white is low - go's back thru switch to ground
here is how the typical 6024 ( 7" round headlight) is wired...
and here is a typical wireing diagram for a relay harness...
so, on to the changes to adapt it to a sami....
on relay:
#86 will need to be hot. you can piggy back from term #30, or the w/bl or w/r wire from factory harness ( depends on what side you connect to).
from factory harness to relay:
red factory wire is neg high beam trigger, connects to #85 in diagram on relay 3
red/white wire is neg low beam trigger, connects to #85 in diagram on relay 1
my zuk has had awefull lighting since i got it. i tested the voltage the other day. with the factory harness disconnected from the lights so there was no draw, i only had 11.7v available. thats a 3volt drop with no load!
( 14.8v @ batt when running ) voltage droped below 9v when pluged in. no wonder i couldnt see at night! :shaking: so today i will go source relays , pigtails etc. i plan to make it plug n play so no cutting of a factory harness would be required.i shuld be able to do some before/after beam shots etc.
I need to do something about my lights...:booo: no time!!!:haha: Oh, and FYI, jack mount's on the Dr side!!!:redneck:
