Headlight relay location

[K75user1979]

Started to tackle this project, got all the goodies together mostly bought from Autozone.  Will be using 2.5mm2 automotive cable and will run dedicated pos and neg cables direct to battery terminals.

On the k75s, the most logical place for the relays is under the instrument damper.  Will drill and tap into this weight for convenient attachment of relays.    Easy from there to connect the headlight cables and make up a new H4 connector with 2.5 cabling.   Wires will be black for both pos and neg so that it fits the rest of the bike and doesn't stand out,   

Last photo is just a tip to store fasteners with their respective washers.  Foam will work too but I had this old cat scratch pad which works perfectly in this case.

[K75user1979]

Doing most of the wiring now leaving 2 of 1.5m pos and neg and 2 shorter neg leads, 1 for parking light and 1 for the headlight connector split between high and low beam.   The original headlight connector wires go straight to relay with the remaining red tails to the new h4 connector.

[Ingo]

Neat!
I did mine with materials on-hand, found some relays is an old moving box, had an in-line fuse holder with a 15 A fuse and ( as electrician) have plenty of different wires on hand. The bike had a charging cable added to batt terminals by PO, I didn't like adding more and more "branches" to the battery terminals. Remove that junk and use 12V outlet on bike for charging.
The new headlight supply is connected at the starter relay inside the relay box under tank. Ground is connected to frame under tank. This leaves the battery terminals clear, only the factory cables are landed on the battery. 

[frankenduck]

I put my headlight relays in the relay box. Only makes sense, right?

I'm not a fan of in-line fuses so I add an aux fuse block next to the OEM fuse block:

[Ingo]

^ more trouble than I'm willing to take...

[K75user1979]

There certainly are multiple ways to tackle this project.  I prefer to run cables direct to battery.   Also, relays are more accessible under the instrument pod rather than having to unplug and lift the tank to do any repairs.   Space is also limited in relay compartment although space could be made. 

Will post pics when done, almost finished.

[K75user1979]

After all of this, no improvement in light output.   The only advantage is to bypass some of the thin and old wiring.

I just don't think it was otherwise worth it.       

[Ingo]

I think it's more about taking load off of the handle bar switch. . .
I also didn't see much difference in the light output, but hope to save the switch in the long run. That would be very expensive and used parts are often not trustworthy.