Frequent website contributor and rival to Marc11 as "Mod King", our Italian ZZR rider "NightRider"
has taken the time to submit detailed tips for the installation of the Diamond Star Headlight modulator.
Read on for the full story...
Written By: NightRider
All the work can be done without need to dismount the fairing, only side cockpit panels and shield must
be removed, just a bit of manual ability and lot of patience is required. The pics are shot while working
on gauges and so the fairing has been removed.
First of all put modulators on the work table, they're very small and the kits contain all what you need to wire:
It's easy to fix the main circuit with bi-adhesive tape provided, Italian ZZRs have lot of space on the right RAM air duct:
DO NOT buy the 2 lights adapting kit, we can use the relays contacts to flash both lights. Remove the shield
and the plastic cover, look inside and locate the 2 lights relays, push them to the gauges and pull them out of
the fairing (they come out not so much, just enough to work) staying in front of the bike the left relay is for low
beam, right is for high beam. In the picture below you see them from behind and so the position is inverted:
Pass the Red & Red-White and Blue & Blue-White wires between gauges and lights and route them to the relays
Remove the rubber cover from right relay and push out the quick-connect terminal with Yellow-White wire, (this
must be done with a very small screwdriver to push in the safety stop of the quick-connect and free it from the plug)
connect this wire to the Blue wire from modulator putting a male quick-connect on it. Put a female quick-connect an
the Blue-White modulator wire and push it in the relay connector where the original wire was.
Do the same with left relay: remove the Red-White wire and connect it with the same color wire from modulator,
put the Red modulator wire in the relay plug.
Now you can reinstall the relays in their normal positions.
Drill a hole in the front fairing, just above the mudguard and install the light sensor.
Route the Purple wire from modulator to right horn and crimp it to the + wire. Crimp the Black (ground)
wire from the modulator to the Black-Yellow wire of the left lamp plug. Drill a hole in the left cockpit panel
to fix the modulator switch. Secure all wires with plastic ties.
