Diamond Star Headlight Module Instructions

Diamond Star Headlight Modulator
Installation Instructions

Step 1

Before beginning make sure your headlight is working properly on "high" and "low" beam.

Step 2

Mount the enclosed adhesive pad to the backside of the Diamond Star modulator unit. Then find a convenient location near the motorcycle headlight to secure the modulator to the motorcycle. Make sure the location selected is suitable for mounting the unit with the double-sided adhesive pad, and when mounted will not interfere with steering or other controls. Assure the mounting surface area is clean and free of grease or oil prior to attaching adhesive pad (adhesive pad will gain 50% of its strength within 30 minutes of placement and will be fully cured in 24 hours.).

Step 3

Using a test light, locate and note the color of the headlight's high and low beam "hot" (+) wires.

Step 4

As a precautionary measure, disconnect the battery's Hot positive (+) lead, to eliminate any possibility of accidentally shorting out any hot wires or terminals during installation.

Note: Before beginning the wire installation you should consider the following. We have provided crimp wire connectors. The use of these connectors is optional. The other accepted method to splicing wires is to solder them. In either case we have provided ample lengths of wire to connect this modulator to your headlight. One further note of caution, if any bare wires are exposed as a result of this installation, wrap the exposed wires with electrical tape to prevent any possibility of a short circuit.

Step 5

HIGH BEAM INSTALLATION

Install two of the "blue female T-Tap connectors" on the high beam "hot" wire near the headlight.

Remove about a 1/4" of insulation and crimp a "light blue male disconnect terminal" onto the "solid red wire" from the modulator unit and connect it to the T-Tap on the high beam supply wire, by pushing it into the female receptacle of the T-Tap.

Likewise, remove a 1/4" of insulation and crimp a "light blue male disconnect terminal" onto the "red & white striped wire" from the modulator unit and connect it to the T-Tap connected on the wire going to the headlight. After installing the T-Taps cut the wire between them

Step 6

GROUND WIRE INSTALLATION

It is very important that the modulator unit is properly grounded. Without the unit being properly grounded some of the internal safe guards could be disabled. A suitable ground, is the ground wire going to the headlight. Use the "dark blue, quick spice connector" and connect the "black" wire from the module to the ground wire of the headlight.

Step 7

Photo-ptic Sensor INSTALLATION

When mounting the photo-optic sensor, consideration should be given to the fact that this sensor needs to sample ambient daylight conditions. If the sensor is placed in a light confining location the sensor will be less sensitive to actual light conditions.

For those motorcycles equipped with a separate headlight bulb housing, an ideal location for the sensor is to drill a 5/16" hole in the base of the headlight housing, and mount the sensor from the inside out, with the sensor eye pointing outward.

For those motorcycles with a fairing mounted headlight, locate a spot just under the headlight and secure the sensor.

These two mounting locations are only suggestions; you can mount the sensor in any location that meets your requirements. No matter what your preference for mounting, the sensor should be mounted with the optic lens pointed downward, and at least 18 inches above the road surface.

Step 8

REMOTE SWITCH INSTALLATION

Selecting a mounting location of the remote switch is totally subjective to each owner's preference; Therefore specific installation instruction shall not be given. The toggle switch should be mounted with the "Green wire" at the top and the "Red wire" at the bottom. When the "toggle switch" is mounted in place, the "OFF" position should be at the Top toggle position. A "switch position" decal has been provided for placement along side of the switch. This decal identifies switch position and functions.

Step 9

SECURE WIRE BUNDLE - for a neater appearance, secure the loose wires from the modulator unit with the provided tie wraps. Check and make sure all wires are secure and do not interfere with steering or controls.

Special instructions for bikes that have headlight(s) that stay on any time the key switch is on regardless of the high / low beam selector switch: (Such as the Honda GL 1800)

1.Connect the headlight modules red wire to the positive source for the headlight(s) that stay on all of the time.

2. Connect the headlight modules red wire with white stripe to the headlight(s) that stay on all of the time.

3. Cap off and do not use the blue or blue with white strip wires.

This will only allow the lights that are on all of the time to flash. This is necessary because connecting all lights would overload the module, and cause both sets to flash out of sequence with each other which would not be legal.

Step 1

Before beginning make sure your headlight is working properly on "high" and "low" beam.

Step 2

Step 3

Using a test light, locate and note the color of the headlight's high and low beam "hot" (+) wires.

Step 4

As a precautionary measure, disconnect the battery's Hot positive (+) lead, to eliminate any possibility of accidentally shorting out any hot wires or terminals during installation.

Step 5

HIGH BEAM INSTALLATION

Install two of the "blue female T-Tap connectors" on the high beam "hot" wire near the headlight.

Remove about a 1/4" of insulation and crimp a "light blue male disconnect terminal" onto the "solid red wire" from the modulator unit and connect it to the T-Tap on the high beam supply wire, by pushing it into the female receptacle of the T-Tap.

Likewise, remove a 1/4" of insulation and crimp a "light blue male disconnect terminal" onto the "red & white striped wire" from the modulator unit and connect it to the T-Tap connected on the wire going to the headlight. After installing the T-Taps cut the wire between them

Step 6

GROUND WIRE INSTALLATION

Step 7

Photo-ptic Sensor INSTALLATION

When mounting the photo-optic sensor, consideration should be given to the fact that this sensor needs to sample ambient daylight conditions. If the sensor is placed in a light confining location the sensor will be less sensitive to actual light conditions.

For those motorcycles equipped with a separate headlight bulb housing, an ideal location for the sensor is to drill a 5/16" hole in the base of the headlight housing, and mount the sensor from the inside out, with the sensor eye pointing outward.

For those motorcycles with a fairing mounted headlight, locate a spot just under the headlight and secure the sensor.

These two mounting locations are only suggestions; you can mount the sensor in any location that meets your requirements. No matter what your preference for mounting, the sensor should be mounted with the optic lens pointed downward, and at least 18 inches above the road surface.

Step 8

Step 9

SECURE WIRE BUNDLE - for a neater appearance, secure the loose wires from the modulator unit with the provided tie wraps. Check and make sure all wires are secure and do not interfere with steering or controls.