Turn Signals in Headlight Assy

[Finally Ridin']

Always wanted to do this, but couldn't find a how-to so here it is. This is my first how-to so feel free to butcher it and give me feedback on how to make it better. I've always noticed that a lot of how-to's have a beer-scale, well I'm here to create the family-scale. Because this should take a single man with no worries about 2 hours to complete whereas my ass took two days! It's all good cause it's finito.

Ingredients:
-22 AWG wire (black and red) ??? on price, I've had spools lying around the garage
-(2) 10mm Orange LEDs $.99 for 15 on eBay and came with 15 510 ohm resistors needed
-(2) 10mm LED housings $.99 for 15 on eBay
-Heat Shrink Tubing $2 at Home Depot
-Electical tape $.99 at Home Depot
-Foil tape $3 at Home Depot
-Wire connectors $3 at Radio Shack

Tools needed:
-Wire strippers
-Crimper
-Soldering Iron
-Heat Gun
-Xacto Blade
-Drill w/ 1/2" bit
-Wire cutters
-Scissors

Here's what the LEDs and housing look like.


Step 1. Insert LED in housing and solder 510 ohm resistor to LONG lead of the LED.


Step 2. Remove headlight assy. I didn't take any pictures of this, but once you take the assy off your bike remove the bulbs and put in a preheated 215 degree oven for 5 minutes. Pry apart with screwdriver.

Step 3. Take off cover on sides of assy. It is one of those plastic push pin things. You will see that it seems as though Yamaha was going to put a signal here because it has info printed for the flasher bulb.


Step 4. Drill hole using 1/2" bit or whatever size LED housing you are using. IMPORTANT Drill the center of the hole from the inside (as if you are looking at the front of the bike). The center from the back isn't in the center. I learned the hard way.


Step 5. I need to make the hole a little bigger and I didn't have a bigger drill bit so I used an Xacto blade.


Step 6. Add foil tape for more reflection. Use scissors to shape foil and put some inside the hole as well as the surrounding outer areas.


Step 7. Insert LED housing from the front.


Step 8. Tighten LED with washer and nut.


edit Step 8A. Put headlight assy back in the oven for five minutes and press back together.

Step 9. Solder RED wire to resistor. Solder BLACK wire to other lead.


Step 10. Put heat shrink tubing on individual wires and use heat gun to shrink.


Step 11. (Optional) Put heat shrink tubing over both wires and use heat gun to shrink. Or you can just use electrical tape.


Step 12. Bend wire toward opening of cover and put the cover back on.


Step 13. Splice into turn signal wires. (Yeah, I know not the best soldering job, but it worked) For left turn signal solder red wire to brown wire and black wire to black wire. For right turn signal solder red wire to green wire and black wire to black wire.


Step 14. Use electrical tape and tape the splice.


Step 15. (Optional) Use electrical tape and tape both splices together.


Step 16. Crimp connectors to wires. I did this so that if I need to take the headlight assy off again I won't need to cut the wire and solder together again.


Step 17. Once everything is crimped go ahead and connect and slap your plastic back on and you're done.


Blinking in the daylight.



Blinking in the night.



Hope I didn't miss anything, but if I did let me know and I will edit.

[Finally Ridin']

For step one, I know it looks like I'm soldering to the short lead, but I shortened the long lead so that it wasn't so long, but I am soldering it to the LONG lead. I tried editing the post, but it wouldn't let me.

[Finally Ridin']

Another edit. Make sure that when you put the assy in the oven it's on a baking sheet lined with foil and that no wires are touching. Why can't I edit my original post so that I can put these corrections in it?

[R6Juiced]

Nice how-to. Very easy to understand and follow. It is kinda funny it took two days. But i understand how it is trying to do stuff yourself just trial and error. Plus, to take time to take pictures during the whole process takes time too. But good job none the less. But you can do the same thing with a socket for a "194" style bulb the same way. Only you don't have to do the headlight in the oven trick. Just drill out the backside of the hole (same place you drilled) insert 194 bulb into socket. And socket squeezes into hole and stays there. You could silicone it in for peace of mind, but it stays there, even after being beaten on the ground a few times. (I had a junk corner piece of headlight I used to test all this) And the cool thing is that the 194 bulbs now come in LED so they are way brighter. And with the socket pushing in from the back, you can theoretically change the bulb if need be without taking apart the headlights again. Sorry to threadjack, and I absolutely love what you did and it looks just great. But thought I would let you know another way to do this. And your way has a very nice clean installation look too. Great Job!

[Finally Ridin']

Appreciate the feedback and suggestions. No feelings hurt here. Yeah, there are probably a number of ways to do it, but I wasn't sure about bulbs and sockets and the like. Great info though for someone that wants to go that route. As for the replacement installation you wouldn't need to take the housing apart. The only reason why I had to take it apart was to install the LED housing, but the actual LED goes in from the rear. You would still have to do some soldering whereas if it was a bulb it would just be a quick switch.

[YAMMAN]

WELL DONE and please don't take this the wrong way.

An esier way to do this is to buy the light bulb sockets from a R1. WITH-OUT removing the head light assembly, simply drill two holes the proper size, wire everything as you explained and put the light bulbs in thier place.

The lights are not as bright with-out the foil tape but they do the job.

[Finally Ridin']

Thanks for the feedback and the alternate way of doing it. This should now give anyone that wants to do this mod three ways they can do it.

[Finally Ridin']

edit - use 150 ohm resistors. Here's a video of them at night

[nAs Liw]

man i wish i had my 05 just so i can do this hahhaha... i have always wondered why they didn't put a Day time running light or anything on the older models... now you can DIY...

nice joe!

[n3wf]

this tutorial is useless with out the pictures. I would really like to do this to my 05.