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Adventuregeek
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162 Posts
Discussion Starter #1 (Edited)
This is a photo guide to installing the turn signal conversion kit from Electrical Connection. This kit adds red LEDs for brake and run functions to your stock rear turn signals, while keeping the turn signal bulb and yellow lens to stay legal. http://www.electricalconnection.com/other-lighting/tsk-star&sport.htm

It can be tricky running the wires through the signal stems, which is the main reason for this post. You can't run the wires next to the socket as instructed - it's too tight and will actually mash the insulation off the wires. There are other ways I'm sure, but this was easy and worked for me.

Let's start with the signal unit off the bike, and the lens removed. As you remove the lenses, go ahead and silicone the LED boards to them (allow time to set before reassembly).

Remove the screw holding the stem retainer clip and pull the clip.

Grab the socket by the little tab and pull that up to remove it. Pull it all the way out, and remove the round rubber seal on the socket wires if present. It won't fit anymore when we're done, and silicone will seal it up.

Now you have to remove the rubber stem from the light housing. I made this easy on myself by cutting a notch in the front of the stem so the lip would push in with less effort. The clip holds the stem in the housing, so wot the heck?



Now comes the good stuff. Carefully cut a groove in the stem on the side that faces the FRONT of the cycle. The wires don't have to fit flush in the groove, just so they don't compress so much when installed.



Now drill a hole in the stem as shown. This will run the wire back inside the stem.



Looks like rats gnawed it, but that's where the wire will run.



Now run the non-connector end of the wire in the side hole and out the light end of the stem.



Next handy trick: push the wire protector tube back into the stem and out the light end. This will help run the wires back out.



Part II follows...
 

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Adventuregeek
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162 Posts
Discussion Starter #2 (Edited)
Part Two!

Now run the turn signal wires and the EC conversion wire back down the tube. I found this made it much easier than trying to shove them down the empty stem.



Now your wires are in place. That big loop in the EC wire will pull into the stem next.



Carefully pull the wires and tube back into the stem. Leave the socket loose with a couple inches of slack.
Leave yourself a few extra inches of slack in the EC connection wire, as you will need to plug in the LED board later.

Stick the socket and the connector end of the EC wire into the light housing, then start the housing onto the stem. Lay the wire flat in that rat-gnawed groove and rejoice at how easily it all goes in.

Apply your favorite weatherproof sealer on the hole and wires before you push the housing on all the way.
Oh, look! EC gave me a tube of silicone!



Now push the stem fully into the housing and wipe off excess sealer. I used some silicone to seal around the wires where they exit the tube (cycle side).
Lotta work to get back where we were, but ain't that wire pretty!



Last, but not least! The EC wire enters behind the socket. Before you replace the retainer clip, tuck the wire under one of the plastic legs that secure the clip. Then run it between the metal reflector and the lens mounting screw towers. This will keep it off the hot bulb and prevent a meltdown.



Plug in your LED board and mount the lens. Happy trails, and ride safe!

 

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Love My Baby
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1,165 Posts
VERY NICE! I've been waiting to convert all my turns to LED, but wasn't certain about the install. I'm looking at the EclipzeLED front turns, and the Dynamic Clusters for the rear, both from Custom Dynamics. The Dynamic Clusters need two wires threaded through the stems so they can be used as brake/running lights as well as turn signals. Check them out HERE. Your install pics are very helpful.
 

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Linkmeister Supreme
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7,960 Posts
Nicely done and explained Tiki Mon.
 

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Adventuregeek
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162 Posts
Discussion Starter #7 (Edited)
Actually, this is about a specific kit which keeps the turn signal bulb, and adds a ring of red LEDS around it. This way you have red run and brakes with yellow turn signals to stay legal. It's a half-conversion, so to speak, and won't affect flash rate.

I've changed the post to make it more clear, thanks for the tip! If you're not familiar with it, the kit can be found here: http://www.electricalconnection.com/other-lighting/tsk-star&sport.htm

If you're going total LED conversion, you'll likely remove the bulb socket entirely. That will leave plenty of room to run wires down the stem, and you won't need to bother jumping through all these hoops.
 
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