Hey Brian,
Having read through the Rosta instructions and your instructions I want to make sure I'm clear on a few things before I dive into it.
1. Regarding the relay for the rear brake lamp, I'm assuming it's necessary to cut the blue brake wire and place the relay between the two ends. Also, does it matter which end of the brake wire connects to which lead (#86 and 87) on the relay? For some reason putting a relay into a ground circuit has my brain scrambled tonight.
What I do is to cut the wire that I want to tap into and then add an additional wire, and finally solder all three wire ends together (the original two wire ends along with the new wire extension). So I would cut the blue wire, strip about 1/2" of insulation off both ends, then add another wire (blue if I had one) and solder them all together. Cover the joint with shrink tubing (if you have it) or carefully with electrical tape and then run the new wire to the Rostra.
As far as which contact on the relay for the blue wire, #86 or #87, you will connect the wire to both of those terminals.
2. On the switch wiring you mention a second relay is necessary for those with an LED indicator. I have the CCS-201 switch My actuator harness supplies two connectors for the switch, a 4-pin and a 2-pin (Lt. Blue & black). I did a little digging and finally found a manual for the CCS-201 online which states the black and gray wires need to be run to ground and the parking light dimmer (aka a switched power source for the LED). Looking at the Rosta manual, it states the two pin plug from the actuator harness is to be "utilized by control switches which require an additional power and ground source such as those containing an LED indicator light or RF models." So wouldn't one just run the gray & black wires from the switch to the 2-pin plug on the actuator harness, and if so where's the need for the relay?
You only need the second relay if you have a switch that has an 'engaged' light on it. The two wires you describe are used to back illuminate the switch with internal LEDs so you can see it in the dark. You do not need a relay. Just connect those two wires to power on the bike (I do not remember which goes to which side, + or - but it is in the instuctions) and the switch illumination will come on with the ignition. There is no dimmer function on a motorcycle of course.
I would suggest you NOT connect any wires to ANYPLACE that is not specified in the tutorial. You will have additional wires and connectors left over on the Rostra harness after installation as this is a universal kit and not streamlined for any specific vehicle.
3. What gauge are the factory wires for the VSS (pink) and the clutch switch (black/white dot)? Need to pick up some Posi-Taps and want to make sure I get the right size. Probably 18ga but it never hurts to double check.
I do not know but they are pretty thin. I would guess 20 gauge although they might be 18 gauge. By the way, put a dab of grease on the end of the Posi Tap before you use it and it will make a connection that will last forever. Grease keeps the wire from becoming contaminated with water after you pierce the insulation.
Best of luck with the install.
Brian