Turn Signal Relocation and other stuff. - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
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post #1 of 11 (permalink) Old 04-08-2017, 11:44 AM Thread Starter
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Turn Signal Relocation and other stuff.

Man... it's just one thing after another!
After doing the Signal Shave the right rear turn signal quit working. The test meter showed power to the connectors but when I removed the turn signal and tested it with a battery, it would not light up. The bulb's filament appeared ok so I figured there is a problem within the wires, plus the brass base of the bulb was corroded to the socket and I was unable to free it so I ordered a new set of cheap turn signals online.
I wanted to relocate the signals to get them well clear of my saddlebags and decided to try the Tail/Brake Light assembly.


I had to trim the opening in the rubber gasket where the wire exits the housing to make it wide enough for the two additional lines and then I had to extend the wires but everything worked.


Notice the new screws in the red tail light. Every time I work on a part of this bike I have been replacing the old chewed up and rusted screws, nuts, bolts and washers. The results are starting to show as these small details give the bike an overall cleaner look.

After checking to make sure the tail and brake lights and both new turn signals were working, I pushed the start button and nothing happened. "Dang It... What now?!

I had taken the brake and clutch handles off and cleaned them up on the wire brush of my bench grinder, so I decided this must have something to do with the clutch safety switch.
When I first got this bike I noticed that I didn't have to pull in the clutch to start it.
It looks like the plastic pin that the clutch handle pushes in was broke off, so the switch is always in the start position. I unplugged the wire harness from the switch to remove it from the bike and found the two tiny (#2 screws) that hold this switch to the underside of the clutch were seriously rusted and I almost messed them up but finally got them to turn.

Using a test meter I found no continuity between any of the three terminals of the switch so I opened it up and all of the contacts had corrosion on them. After cleaning everything up I got good readings on the meter and plugged the switch back onto the line and the bike started up just fine. Back to Home Depot where I got some stainless steel, #2x14mm, beveled head screws and reattached the switch into its place under the clutch lever and I was on my way.
Another successful mission!

37K+ Miles
Relocated R&R
LED License Plate Bolts
Solar Panel Battery Charger
Relocated new Turn Signals to Taillight Housing.
Replaced original round, chrome rear view mirrors with black, squared mirrors

Avatar: George The 3rd
June 2006 - Sept 27, 2013

Current Ride: 2005 Kawasaki Vulcan 750
4th Ride: 1981 Kz1000 LTD (2008 - Storage)
3rd Ride: Wife (1999 - 2005)
2nd Ride: 1982 Kz1000 LTD (1983 - 2004)
1st Ride: 1977 Yamaha XS-650 (1981 - 1983)

Last edited by majdsaster; 04-08-2017 at 11:49 AM.
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post #2 of 11 (permalink) Old 04-08-2017, 12:13 PM
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looks good

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1986/5 Vn700/750 Frankenfook cross eyed bitch "Mellisa Fayhe"
I am a BIKER and i'm proud.FREEBIRDS MC CENTRAL NY

lowered with progessive 412 10" shocks
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post #3 of 11 (permalink) Old 04-08-2017, 05:30 PM
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wow, nice, I love the look. I think I found my next project. Been wondering how to pull the lights back to clear for hard boxes :P

On a side note, anyone know a good reliable vendor for LED Signals; Front and back?

CURRENT BABY: 2006 Vulcan VN750, 13k miles.
PREVIOUS Big BABIES: 77 Kawasaki KZ400, 88 Honda Hurricane 1000, 78 Yamaha XS650, 84 Honda Goldwing 1000, 86 Suzuki GS550L
PREVIOUS Lil Babies: 84 Honda Passport 70 (modified the heck out of it), 08 Yamaha Zuma FX50 (just sold)
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post #4 of 11 (permalink) Old 04-08-2017, 05:33 PM Thread Starter
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Quote:
Originally Posted by ZmanInFl View Post
wow, nice, I love the look. I think I found my next project. Been wondering how to pull the lights back to clear for hard boxes :P

On a side note, anyone know a good reliable vendor for LED Signals; Front and back?
I used some fender washers on both sides to reinforce the plastic housing. Pretty happy with the job. The signals are small and cheap, ($13.00) for the pair of them but I might replace them with a set of LED units at some point.

37K+ Miles
Relocated R&R
LED License Plate Bolts
Solar Panel Battery Charger
Relocated new Turn Signals to Taillight Housing.
Replaced original round, chrome rear view mirrors with black, squared mirrors

Avatar: George The 3rd
June 2006 - Sept 27, 2013

Current Ride: 2005 Kawasaki Vulcan 750
4th Ride: 1981 Kz1000 LTD (2008 - Storage)
3rd Ride: Wife (1999 - 2005)
2nd Ride: 1982 Kz1000 LTD (1983 - 2004)
1st Ride: 1977 Yamaha XS-650 (1981 - 1983)
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post #5 of 11 (permalink) Old 04-08-2017, 06:06 PM
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DANG IT. After seeing your post I went out and put on my thinking cap to find out that mine are already pulled back with extensions; can we say bonehead. When I measured out the boxes I was looking at the back side of the light would have been right on it. As you can see in the picture that my current bags do not have much space. Any tips or ideas?
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CURRENT BABY: 2006 Vulcan VN750, 13k miles.
PREVIOUS Big BABIES: 77 Kawasaki KZ400, 88 Honda Hurricane 1000, 78 Yamaha XS650, 84 Honda Goldwing 1000, 86 Suzuki GS550L
PREVIOUS Lil Babies: 84 Honda Passport 70 (modified the heck out of it), 08 Yamaha Zuma FX50 (just sold)
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post #6 of 11 (permalink) Old 04-08-2017, 06:19 PM
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ZMan: Custom Dynamics is a good place.
ZmanInFl likes this.

TOC MCCTs
Saddlebags, hard mounted
Fork mounted tool bag (now hard mounted)
Relocated rear turn signals
LED turn signals, brake lights and running lights
LED license plate frame
Engine Guard and Highway pegs
National Cycles Low Boy Heavy Duty windshield
Home made lowers (nice)
Custom seat (made by a local guy)
Iridium plugs (DPR7EIX-9)
Shenko 230 Tour Master tires at 11,123 miles
Splines lubed at 11,123 miles
Luggage rack
Light bar with LED lights
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post #7 of 11 (permalink) Old 04-08-2017, 06:23 PM
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Quote:
Originally Posted by Chris and Shim View Post
ZMan: Custom Dynamics is a good place.
Thx. will check em out

CURRENT BABY: 2006 Vulcan VN750, 13k miles.
PREVIOUS Big BABIES: 77 Kawasaki KZ400, 88 Honda Hurricane 1000, 78 Yamaha XS650, 84 Honda Goldwing 1000, 86 Suzuki GS550L
PREVIOUS Lil Babies: 84 Honda Passport 70 (modified the heck out of it), 08 Yamaha Zuma FX50 (just sold)
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post #8 of 11 (permalink) Old 04-09-2017, 10:22 AM Thread Starter
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Quote:
Originally Posted by ZmanInFl View Post
DANG IT. After seeing your post I went out and put on my thinking cap to find out that mine are already pulled back with extensions; can we say bonehead. When I measured out the boxes I was looking at the back side of the light would have been right on it. As you can see in the picture that my current bags do not have much space. Any tips or ideas?
I'd get a length of 1" aluminum angle-iron and attach it across the underside of that luggage rack, as far back as you can, to use as a mounting bracket for the turn signals.

37K+ Miles
Relocated R&R
LED License Plate Bolts
Solar Panel Battery Charger
Relocated new Turn Signals to Taillight Housing.
Replaced original round, chrome rear view mirrors with black, squared mirrors

Avatar: George The 3rd
June 2006 - Sept 27, 2013

Current Ride: 2005 Kawasaki Vulcan 750
4th Ride: 1981 Kz1000 LTD (2008 - Storage)
3rd Ride: Wife (1999 - 2005)
2nd Ride: 1982 Kz1000 LTD (1983 - 2004)
1st Ride: 1977 Yamaha XS-650 (1981 - 1983)
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post #9 of 11 (permalink) Old 05-26-2017, 03:59 PM
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I love it and I'm going to do the same....
What are your bags, and dimensions, I like them.
Thanks, Rick
post #10 of 11 (permalink) Old 05-26-2017, 06:23 PM Thread Starter
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Quote:
Originally Posted by [email protected] View Post
I love it and I'm going to do the same....
What are your bags, and dimensions, I like them.
Thanks, Rick
I will measure the bags this weekend, Rick, (I’m at work right now). I bought them off Ebay but I might still have the invoice around. I’ll have to look when I get home.


Here's the bags I got. Found them on EBay, one of the images shows the dimentions;

http://www.ebay.com/itm/16-W-MOTORCY...NWwkJO&vxp=mtr

They have the carrying capacity I wanted and have worked out ok for taking weekend trips, but I was disappointed by how fast all those studs rusted up.

37K+ Miles
Relocated R&R
LED License Plate Bolts
Solar Panel Battery Charger
Relocated new Turn Signals to Taillight Housing.
Replaced original round, chrome rear view mirrors with black, squared mirrors

Avatar: George The 3rd
June 2006 - Sept 27, 2013

Current Ride: 2005 Kawasaki Vulcan 750
4th Ride: 1981 Kz1000 LTD (2008 - Storage)
3rd Ride: Wife (1999 - 2005)
2nd Ride: 1982 Kz1000 LTD (1983 - 2004)
1st Ride: 1977 Yamaha XS-650 (1981 - 1983)

Last edited by majdsaster; 05-27-2017 at 11:37 AM.
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