Step 1: Parts Needed
- 12VDC/125VAC 10A SPDT Mini Relay (275-248)
- 1000 microfarad 35V 20% Radial-lead Electrolytic Capacitor (272-1032)
- 10K ohm 1/2W 5% Carbon Film Resistor pk/5 (271-1126)
- Project Enclosure - 4x2x1" (270-1802)
In addition, you'll need a garage door opener. I used a Chamberlain Universal Garage Door Opener that I found at Lowes.
For a nice, clean installation, I'd pick up some 18g hook-up wire, heat shrink tubing, and some wire-tap-in's. You'll also need a soldering iron and solder for making the connections.
Step 2: Wire Up the Relay
To make it easy to keep track of what was what, I used green hookup wire to run leads that would be attached to button on the garage door opener. These are attached to pins #87 and #30 and are about 3" long. The black wire is going to go to the capacitor and resistors (and then on to the headlight common wire). It is attached to pin #85 and is about 3" long. The red wire will run all the way outside of the project box into the hi-beam circuit, so it's about 12" long and it is attached to pin #86. All connections have been soldered and then heat shrink tubing applied.
Step 3: Wire Up the Capacitor and Resistors
NOTE: Be sure to keep track of which side of the capacitor is positive/negative (the negative side is marked). This is important for the next step as the negative side is to be connected to the relay.
Step 4: Connect Capacitor / Resistor Pack to Relay
Step 5: Connect Relay to Garage Door Opener
On the back of the circuit board, I located the two contacts on the backside of the button that would trigger the opener. You can figure it out by using a short piece of wire to connect the two points. If it's the right pair, the garage door opener will trigger. Make sure you test this before soldering it - as you can see from my image below, I attached to the wrong contact point at first and had to come back and fix it later.
Step 6: Install Into Project Box
When done, add the cover to the project box and you are ready for installation in the motorcycle.
Step 7: Installing the Project Into the Motorcycle
If you go to the hi-beam on the lite, you will need to determine where you want to tap into the circuit. On my Harley Fatboy Lo, the wires run directly from the switch on the handlebar through the forks, right into the headlight enclosure. I found the best place to tap in, was right in the housing, directly behind the light enclosure. I took out the headlight enclosure and accessed the wires the same way you would if you were changing the bulb.
Next you will need to determine which wires you need to tap into. I have an H4 bulb, so the two outside contacts provided me the "common" wire and the "hi-beam" wire. Figure out what kind of bulb you have and head to Google for some help with the wiring diagrams for your particular bulb type.
Using the wire tap-ins, splice the black wire from the project box into the common (white wire in my bike) and the red wire from the project box into the hi-beam (black wire on mine). I had two black wires going into mine, but opening the connector I found they both went to the same contact point, so it did not matter which one I tapped into.
After that, turn on the bike and give it a test. I found that mine would only work if there was a bulb installed. Turn your lights on normal and then flip your hi-beam on and then back off to trigger the garage door opener. You should hear the relay click and ideally the garage door should open.
Once you have everything tested, place the project box into the housing behind the headlight fixture and put it all back together. I'd include photos of the finished product, but the beauty of it is - there is nothing to see :)
NOTE: I was initially wondering how hot it got in there and if that would be a problem, but after careful inspection of the other plastic and wiring exposed in there, I did not see any damage from heat so decided to give it a try. After returning from a 280 mile trip where we used the hi-beam extensively, I'm happy to report that there was no sign of any overheating with the project box or components.