Since Some of You Asked- Istalling a Fused Relay for Additional Power Hookups - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 12 (permalink) Old 02-03-2017, 03:45 PM Thread Starter
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Since Some of You Asked- Istalling a Fused Relay for Additional Power Hookups

This is for my 2013 Voyager, but as far as I can tell this will work with other-year Voyagers and Vaqueros. The only difference on the Vaquero is where the final connector leads to (I imagine a saddlebag).

I recently installed a fused, relay connection to the trunk of my Voyager to allow me to connect additional electrical items as well as the ability to hard-wire certain things like a phone and GPS charger. I will try and go step-by step.

The first thing I needed to do was make the wiring harness. I can post a parts list if anyone wishes, but if you don't want to go through the hassle of making one yourself I highly recommend Eastern Beaver (Home). I have used 2 of their harnesses in the past on other bikes, and basically just copied what I previously purchased for this setup.

STEP 1- Finding a Location for the Relay

I decided to install the relay in the toolkit space, just above the battery. The old kit is a bit of junk anyways, and I keep a set of tools in my saddlebag so it made the best sense for me. The only issue I faced, was how to run the wiring through it. Basically, I drilled 3 holes; one for the relay wire- one for the wiring to the battery and one for the wiring run to the trunk. This is a pic of the initial placement after I drilled the holes and connected the wiring to the battery.
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post #2 of 12 (permalink) Old 02-03-2017, 03:49 PM Thread Starter
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STEP 2- Connecting the Relay Wire

I looked for a close-by connection that would show 12v when the ignition was on, and found a connector right next the battery housing on the right side of the bike. I am guessing it's a power source for the heated seat, but I am unsure. All I know, is that it works lol. I crimped a connector on the relay wire, stuck it through the hole I drilled in the old tool kit space, connected it to the plug and covered it up with electrical tape.
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post #3 of 12 (permalink) Old 02-03-2017, 03:53 PM Thread Starter
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STEP 3- Running the Cable to the Trunk

This was the easiest part. All I did was follow the existing path of the antenna and brake light to the trunk, and stuck the cable through the same opening. I did have to remove the trunk plate though. I ended up replacing the pop-rivets with ones that screw tight, in case I needed to remove the plate again in the future.
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post #4 of 12 (permalink) Old 02-03-2017, 03:57 PM Thread Starter
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Step 4- Adding Accessories

This pic shows my cigarette plug installed. I have, since then installed a fuse-block instead so I can power more than one item.

That's about it. It really wasn't too difficult. The hardest part was trying to figure out where to initially install the relay connection. Since the toolkit was right over the battery, it made the choice pretty simple for me.
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post #5 of 12 (permalink) Old 02-03-2017, 04:07 PM Thread Starter
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I should finally add, that the wiring harness I made was copied after this one-

Eastern Beaver sells theirs under "Fuse Panel Wiring Kits"

I also have no connection with Eastern Beaver, and get no compensation for their endorsement.
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post #6 of 12 (permalink) Old 02-03-2017, 10:29 PM
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Here's mine... There are accessory connectors under the seat, so I just plugged it into those using crimped on bullet connectors. There's a fuse in line, so I don't see any issues. I mounted the holder by taking the plate out of the front of the trunk and bolting it through, and the USB outlet is nicely out of the way of any luggage and at the same time easily accessible when required in the front right corner of the trunk.

If I had to do this again, there are similar looking but dual USB outlets now available on Ebay for cheap, with free shipping out of China. I used to have another single one in the front left cubby, but took it out recently to give me more room in there - I never used it much anyway, and the one in back is easier to use.

The wiring is tucked nicely out of the way under the front ledge of the trunk tray.
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post #7 of 12 (permalink) Old 02-07-2017, 11:09 PM
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Very good write-up. For folks like me with little to no electrical knowledge, how does a relay help when installing accessories?
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post #8 of 12 (permalink) Old 02-08-2017, 06:19 PM Thread Starter
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Hi Glen,

Basically, a relay is just an electric switch. What it does, is allow one to connect the main power to the battery instead of from a source that is tied to the ignition. For example, let's say I want to be able to use a small DC-powered air compressor or an inverter to run some AC-powered stuff. If I connected the power to an existing circuit by tapping off of it, I can't guarantee I wouldn't blow a fuse....or worse fry the wiring harness. By installing a relay, the power goes straight off the battery on a 30a circuit and only comes on when the ignition is running. All I have to do is make sure the engine is running and charging the battery.

Jer

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post #9 of 12 (permalink) Old 02-09-2017, 02:05 AM
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Thanks Jer. That helped a lot.

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post #10 of 12 (permalink) Old 02-09-2017, 10:56 AM
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IF I remember correctly, my 2015 Voyager got a fused and ignition powered battery source under the seat straight from the factory. The cables has been right of the battery looking in driving direction.

Perhaps or could be some differences between europe and US models ?


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