Star Headlight & Lantern 7400 Star Lase User Manual

Page 7

-4-

Wire Harness

CONTROL

CABLE

INLET

BARE (Ground)

BROWN (Enable Rear)

WHITE (Synch)

ORANGE (Enable Front)

RED w/GREEN (Pattern Select)

PURPLE (High/Low Select)

RED (Power)

BLACK (Ground)

Not Used
Green
Green w/Yellow
White w/Brown

EMPTY

PATTERN SELECT WIRE FROM CIG PLUG

EMPTY

CIG PLUG +12VDC

CIG PLUG -12VDC

Wire

Jumpers

CIG PLUG CONNECTIONS

HARD WIRE CONNECTIONS

(Wire Harness Replacement CONT’D)

1. To replace the wire harness you will need to access the inside of the lightbar. Remove

the endcaps by removing the four screws from each end and the screws that hold the top
extrusion on the lightbar (ex. 6 screws on a 46” lightbar), and carefully lift the top off of
the lightbar (as shown on the previous page).

2. Locate the end of the lightbar with the wire harness attached to it. The terminal blocks,

which you will be making your wire terminations to, are also

located at this same end. The two harnesses enter the bar through separate openings
and are each fastened to the extrusion with a small clamp.

3. Remove the screw that attaches the cable clamp to the extrusion.

4. Loosen the screws that secure the wires in each terminal block, and slide the old

harness(es) out through the inlet.

5. Run the new external harness up through the wire bushing into the base and into the

terminal blocks. Take extreme caution that none of the wires frays at the end, shorting
out to the adjacent terminal and/or adjacent wire.

6. Strip each wire 1/4". Connect each wire to the proper terminal, as indicated in the

diagram below, by inserting the stripped portion of the wire under the rising clamp screw
and tightening down the screw. No wire terminals are needed for connecting wires to this
terminal block.

Be sure to check that no strands of wire are loose and shorting to the adjacent

terminal or to the base of the lightbar.

7. Once your new wire harness has been connected to the lightbar, secure it with the cable

clamp and reassemble the top extrusion and endcaps. Then you may go back to the
Wire Connections section.