1300 Electrical Section:Changing Headlight, LEDs Turns, Flasher relay fix

[grundle]

Ok could not find a write up on this and just spent the last hour wanting to bang my head on the driveway....

1) There are either 2 or 3 screws holding the headlight assembly in place, 2 inside the headlight assembly at the top and possibly 1 at the bottom. You do not need to remove the bottom screw, there is also a tab connector at the bottom, simply remove the top 2 screws the assembly will open towards you. A little bit of jockeying and the assembly will come out (I removed the light bar and headlight to find this part out)

2) There is a rubber gasket where the wiring goes into the headlight assembly. Roll this backwards (away from the light) and it will expose a brass colored spring type thing. This brass spring holds the light in the assembly. Push down on the tab will release it and it will unclip, carefully roll this to the side (one side is hinged) being careful not to rip or tear the rubber sleeve.

3) OK now all you have to do is pull the bulb from the connector. This is or was for me a major pain, kept thinking I was going to break it or that there was something else holding it in... Nope just a major pull.

4) Put new bulb in, make sure sleeve is over the end of the bulb (leave sleeve rolled back). Reclip brass spring, roll rubber sleeve back and rescrew assembly.


Hope this helps someone I know I sure could have used it.

Grundle "going back out to put the turn signals and headlight mount back on"

[horseman8m]

In most states the dot has a certain speed that your turn signals can flash,
and on most motorcycles if you change your turn light bulbs to LEDs your
flasher relay will not work or will flash to fast .
LED turn light bulbs draw very little watts and most flasher relays require
heat of two light bulbs to cycle the flashers, they are called thermal flasher relays, and
thay will not work with LED light bulbs
here is a $10. fix for the "Too fast flasher"


First find your flasher relay on your bike and remove it , look on the bottom and see if it has two prongs or three.
Most bikes will have two you will need to go to your auto parts store and get an "electronic flasher" (EL12).
For 3 prong you will need electronic flasher (EL13).
I went to @dv@nce auto parts and in the aisle with the interior light bulbs was the ten dollar flasher.

http://i246.photobucket.com/albums/gg105/horseman8m/flasher-01.jpg

The plug for the original flasher was smaller the the new one so i got some solder less connectors and
some spare wire, and on the bottom of the flasher there are plugs one marked with the "X" , and the other with an "L".

http://i246.photobucket.com/albums/gg105/horseman8m/flasher-02.jpg

I plugged the "X" into the side with the +12volts and one marked with the "L" into the other one (load). and
for the three prong type , the "P" is connected to the indicator light.

tape it up out of the way
http://i246.photobucket.com/albums/gg105/horseman8m/flasherinstalled-01.jpg

what do you know ,,,,, IT worked.

[horseman8m]

LEDS turn signal wiring (two wire leds work as a three wire)



Have you ever wanted to put on some cool after market front LED turn signals,
like these in the first picture, E8ay has them for under $10. BUT look,,,,


http://i246.photobucket.com/albums/gg105/horseman8m/LED-005.jpg

Everyone of them are TWO wire and most states require both marker lights and turn signals.
go ahead and get them and pickup a few things to get the LEDS to work for you.

6 ea ... 3 Amp diodes (rectifier type) 1N5401
2 ea .... 1/4 watt 270 ohm resistors
5 ea,,,,,, small bayonet connectors (male ends needed)
2 ea ,,,,,,,,solder-less butt connector
6 inches.. orange wire 18-22 gauge (no smaller then 22 gauge)
6 inches....blue wire 18-22 gauge (no smaller then 22 gauge)
6 inches....green wire 18-22 gauge (no smaller then 22 gauge)
6 inches....black wire 18-22 gauge (no smaller then 22 gauge)
6 inches ... 1/4" heat shrink
8 inches ... 1/8" heat shrink
Total in parts about $5.

Solder and soldering iron

Color of the wire is NOT important as long as you put the right wire in the right place.
This should work on most motorcycles.

cut the orange wire in half and strip the ends ( two - 3" wires)
see fig 1
twist the ends of two diodes together with the stripe up and twist one orange wire to
that end and solder them together.
with the other orange wire twist and solder that to one of the bottom ends of a diode.
take one resistor and twist and solder it to the other diode bottom end.
cut two 1" green wires and strip the ends.
with one of the short green wires twist to the bottom of the resistor.
lay it down so it looks like the picture in fig 1
now do this again but now instead of orange wire use blue on this one.
http://i246.photobucket.com/albums/gg105/horseman8m/diodes-res-01b.jpg

you should have two of fig1 one with orange wire on top and left bottom and a
green wire on the right bottom and one with blue wire on top and left bottom and a
green wire on the right bottom . Good now set them aside for now .

cut 2" of the black wire , and strip the ends.
cut the rest of the green wire in half , this should give you two 2" sections
and strip the ends.
as you see in fig 2 ,,, twist each end of the black wire on the top of the
a diode (stripe up) and solder (E) to (F).
then twist and solder the two green wires to the bottom of the diodes .
you should have fig 2

http://i246.photobucket.com/albums/gg105/horseman8m/diodes-res-02b.jpg


Now place the orange wires of the fig 1 to the left and the blue wires of the
fig 1 to the right so that both resistors are on the inside and this is where you
need two 2" sections of 1/4" heat shrink and slide them onto the resistors so
they cover the fig 1 diodes ,, now set fig 2 at the bottom and twist and solder
the 1" green wires to the tops of the fig 2 assembly (E) and (F).
SEE FIG 3:

http://i246.photobucket.com/albums/gg105/horseman8m/diodes-res-03b.jpg

you must use heat shrink to keep things from getting wet and it makes the unit stronger.
Heat and shrink as you go,, looking at fig 4 you will see that the heat shrink works from
the bottom up. now cut 2" section of the 1/8" heat shrink, slide it up the green wires
(G) and (H) of the fig 2 diodes first, then the heat shrink from fig 1 resisters over the
top of the black wire and the fig 2 diodes and going up with the same heat shrink
covering the resisters and the inboard diodes on the fig1. now two sections of 1/8"
heat shrink to cover the diodes and wires of (C) and (D) to cover the outside
diodes of the fig 1 assembly. then cut two 2" sections of 1/4" heat shrink and
cover the (A) and (B) wires and over half way down the fig 1 diodes.

The fun part is done now you should have ,,,
A ,,,, orange wire
B ,,,,, blue wire
C,,,,,, orange wire
D ,,,,,,,blue wire
G ,,,,,,, green wire
H ,,,,,,green wire
as seen in fig 4.

http://i246.photobucket.com/albums/gg105/horseman8m/FINALturn-01b.jpg

remove the top inside screws to your headlight , unplug it and set aside.
strip the ends of the LEDs neg - end and twist together and crimp a male bayonet
connector on the end. You can see the wires that go to the ground it is the
only double bayonet connector there, .
wire (A) goes to the left turn LED pos+ wire, splice and crimp solder-less butt connector
wire (B) goes to the right turn LED pos+ wire, splice and crimp solder-less butt connector
wire (C) crimp a male bayonet connector then it goes to the orange with black wire .
wire (D) crimp a male bayonet connector then it goes to the blue with black wire.
wire (G) crimp a male bayonet connector then it goes to the orange with white wire.
wire (H) crimp a male bayonet connector then it goes to the blue with white wire.
.
print this one out (fig 5 ) and have on hand as a ref.
http://i246.photobucket.com/albums/gg105/horseman8m/FINALturn-02-colorsb.jpg

reinstall headlight . try it out .. if you have a fast turn signal flash then you will need to change your
flasher relay , to do that go to this link ..
http://mcdarksiders.forumotion.com/general-motorcycle-tech-information-f14/leds-flasher-fix-t2900.htm


that should fix you up and your new leds should last 100,000 hours.
NOTE: some motorcycles have other color codes, so just go with the color wires that are on your bike.
good luck, drive safe,
Horseman (Jonathan)

[trucktrain]

:congrats: Very well done. Thanks for the info.