I really don't want to smoke my bike <grin>. I smoked a trike once and I think it gave me cancer. I'm not sure I understand the pilot circuit idea. Am I close? Right now, as I've wired the circuit, it's hot all the time until she turns off her Gerbing thermostat controller. I see a dead battery in our future. Thanks again!
Bill'ster, Good! you are working the problem. Like they say when your airplane is spinning out of control, KEEP FLYING! never quit flying the plane. So hang with me and I will walk you thru this step by step. The DC current will flow in the order that I list. Think of it like water it can only flow one direction and only when it has a complete circuit.
1. Attach a new RED 16 guage wire (larger if needed) wire directly to the battery positive post. Preferably use a connector as we dont like stray wires.
2. Wire to an inline fuse of proper Ampacity (is that a word?) for the specific load (v*a=w) you intend to control.
3. From the fuse wire to a pilot relay Normal Open SPST contact (autozone $5). The red wire goes to the Contact terminal not the 12vdc coil. The contact is the LOAD side of the relay. The coil is the PILOT side.
4. From the switched contact (outlet) of the relay continue your RED 16gauge wire to what ever connector you plan to plug your accessorie in.
5. This connector should have two terminals, RED-12vdc hot and Black-12vdc ground. Do not run the black wire to the frame. (whole 'nuther topic later). Run a 16guage (or larger) BLACK wire from the connector all the way back to either the bikes common terminal or the battery Negative post. There is a common terminal in the wiring area under the seat/side cover. It is convenient. Use proper electrical connectors. Loose wire strands are truble.
OK, so now the Load side of the wiring is complete. Next the Pilot wiring.
6. Dig out the wire that feeds the license plate nite lite
. NOT the brake or running tail lamp. Connect a new wire 18-20gauge to this circuit (color the same).
7. Run this new light duty PILOT wire all the way up to your handle bar or where ever you care to mount your switch. Since it is never going to be hot when the bike is keyed off, it doesn't matter that it is in the open, ie convenient.
8. From your newly installed Pilot Switch (outlet) run this new color wire all the way back to the Pilot Relay and connect it to the 12vdc COIL.
9. Run an additional 18-20gauge Black wire from the other side of the coil to the bikes common terminal.
10. Never use the frame as a ground / return line. There are a host of problems associated with this method. Yes it works.. sometimes.. when it doesn't, it will leave you stranded, high and maybe not dry. Just don't do it.
OK, so now your wiring is complete. Put the key in the bike, turn it on. The pilot duty switch can now toggle the pilot relay ON and OFF. Your accessory can function... or not, you are in control.
Turn your bike key off. The pilot switch is now dead. The pilot relay is just as dead. Nobody, not even God can turn your accessorie on w/o that dang bike key. Well, maybe He can.? but he has the keys to everything anyways.
So now you are an expert! Your bikes wiring harness is safe from anything happening, even you. If you have ever had to replace a complete wiring harness, you wont ever plug just anything into it. I have. muey 'spensive.