Star Headlight & Lantern 7400 Laser M - Manual (Page 6)

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(Wire Harness Replacement CONT’D)
2. The wiring harness will connect to one or more terminal blocks inside the lightbar. All of
the wires coming from the harness are terminated on one side of the terminal block and
the wires leading to the internal components terminate on the opposite side of the
terminal block. The Wiring Harness chart on page 1 lists the wire colors from the harness
and indicates the function of each. Before removing the old harness, note the wire
color and function for each terminal.
3. Loosen the screws on the HARNESS SIDE of the terminal block and remove the harness.
Remember that there may be “dead” wires from the harness connected to the terminal
block inside your lightbar, but there will be no wires connected to the terminal across from
them. These are extra wires in the harness that are not used. Replacing these wires in
your new harness is not necessary.
4. Run the new external wires up through the wire bushing into the base and to the terminal
block(s). Use the Wiring Harness chart to help determine where each of your new wires
should be connected.
5. Strip each wire 1/4". Connect the external wires to the proper poles of the terminal block
by inserting the stripped portion of the wire under the rising clamp screw and tightening
down the screw. Note that 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.
6. Once your new wire harness has been connected to the lightbar, secure it with the cable
clamp and reassemble the top extrusion and endcaps.
From Lightbar Components
R
e
m
o
v
e
T
h
e
s
e
B
L
A
C
K
From Wire Harness
Please note that your lightbar may have more or fewer
wires in the harness or from the lightbar, and it may or
may not use terminal jumpers as pictured below.