Step 1: Install a fuse holder right at the battery for protection. I bent a terminal at a 90 degree angle and hid it under the stock connection at the battery to prevent shorts. Then from the fuse holder I ran a lead up to the headlight, above the airbox and under the fuel tank with it all shrink tubed or taped up all the way and zip-tied to existing wiring and cables. The pigtail at the top of the picture is for a trickle charger connection. I taped a spare fuse to the outside of the fuseholder.
Step 2: I rewired the headlight. Stock it is wired into the AC coming from the alternator before it goes to the rectifier/regulator to be converted to 12V DC. It is wired only to high beam(blue wire), and although there is a low beam element, no wiring is provided to the white wire which is only on the headlight side of the plug in connection. I ran a constant DC to the Baja Designs switch, and to the Acewell for memory. I then wired the switch to the Acewell (using the taillight wire of the switch which I didn't use for the taillight, its still stock) to turn the Acewell on when either high or low beam is turned on. Low and high beam were wired to the switch as well.
The white zip ties are where the new wiring is.
Step 3: I built a new bracket for the Acewell, using the aluminum stock, and mounting it to the stock headlight bolts, which were replaced with 1/4" longer metric bolts from the hardware store.
Step 4: Put it all back to together with new grips, and slightly tweaked Fastway brackets to fit a little better at the handle bar clamps. Now the Acewell is lower, and now I can turn on the Acewell, or headlight without the engine running. I can use either low beam or high beam which is nice for a backup if one burns out, and for low or higher speed riding at night. The stock cheap kill switch is gone and I have a fused DC source up at the headlight if I want to add any GPS or other accessories. I can also run the bike with no lights, which I can't really find a reason for now.
The Baja Designs switch which also has a kill switch built into it is part number 12-0050. Radio shack has shrink tubing and quality connectors for wiring.
