Running Lights Conversion

[Tiny Tim]

FRONT RUNNING LIGHT / TURN SIGNAL CONVERSION

Before I start, I should point out that some people feel that having the front turn signals illuminated by default (running lights) may present a hazard by way of confusing other road users. If that’s your opinion, then this project is not for you. For my part, I have road tested this for some 500 miles over a two week period and have encountered no such problems. Should I change my mind then “normal service” can be restored by moving a single connector on each relay.

PARTS
2 X 5 PIN AUTO RELAYS (typically Halfords HEF557 @ £5.69 each
2 x 6 ohm LOAD RESISTOR (typically M&P Motorcycles Swansea  - Arcol 157-550 @ 3.49 each)
10 x RED 6.3 mm FEMALE CRIMP SPADES
2 X SCOTCHLOK SPLICE CONNECTORS
2m 1.5 mm AUTOMOTIVE WIRE
100 mm SELF ADHESIVE VELCRO
HEAT SHRINK
SOLDER


TOOLS
SOLDERING IRON
CONNECTOR CRIMPING TOOL
WIRE STRIPPERS / SNIPS
ALLEN KEYS TO REMOVE BOLTS

You may find a Multimeter handy in the event that you encounter any snags.

My basic tip with any work of this kind is to take copious photos and notes BEFORE you start to provide a “line in the sand” point which can be returned to if it all goes Tits-Up!

The skills required for this project are basic handyman level with very little electronic skills required.

As long as the ignition and the Hazard (4-way flashers) are switched off, there will be no need to remove or disconnect the battery but should you wish to do so, feel free.

Whist it is possible to complete the work through the mirror housing aperture with the mirror hinged out of the way, it is easier with the mirror front housing removed which is not difficult.

BASIC PRINCIPLE



The basic principle is that the turn signals are replaced by a five pin relay which therefore has a changeover contact. The contact that we need is the normally closed one. That’s to say that it is “made” until the relay operates and then re-makes once the relay releases.

The relay coil is connected to the two wires that feed currently feed the turn signal. If left like this, the turn signal will flash at an increased rate as the resistance of the relay doesn’t match the resistance of the turn signal bulb. To that end, a 6Ω resistor is connected across the terminals of the relay to restore status quo and therefore the correct flash rate.

Relay Details


Resistor Details


MOUNTING
The resistor and the relay can both be mounted via self adhesive Velcro in the mirror housing, there’s ample room. I suggest that the two drilled fixing tabs on the resistor are cut off and filed flush with the sides as they are not required in this application.

METHOD
1.   Open the mirror by pulling the mirror towards the rear of the bike

2.   Disconnect the connector to the turn signal by pressing the centre of the spring retainer and pulling the connector away from the fitting

3.   Remove the single large 5mm screw to allow the turn signal lens and body to be removed forward

4.   Remove the single 5mm bolt holding the front mirror / turn signal housing which is now accessible and pull forward on the housing to release the front locate lug.

5.   THIS IS THE POINT TO TAKE ANY “LINE IN THE SAND” PICTURES AND NOTES

6.   Cut the two wires going to the turn signal plug about 25mm from the plug

7.   Using solder and heat shrink, extend the two wires from the plug.  The black conductor should be extended by around 500mm and the Green striped one by 100mm. The short wire should have a 6.3mm female spade terminal crimped onto the other end of it

8.   Again, using solder and heat shrink, extend the other ends of the two cut wires that were going to the turn signal by 100mm.  That ‘s the two cut turn signal wires from the wiring harness.

9.   Extend the two tails of the resistor to 100mm each measured from the resistor

10.   Take one leg of the resistor tail and the black of the extended turn signal harness wire and crimp one 6.3mm female spade onto them COMBINED - i.e. – two wires into one crimp.

11.   Repeat step 9 for the Green striped harness wire and the other leg of the resistor

12.   Clean the area on the base of the mirror housing with a dry cloth and fix one half of the double sided tape as shown below



13.   Remove the two fixing lugs from the body of the resistor and file the sides flush

14.   Fit the corresponding double sided Velcro to the base of the resistor and trim to size


15.   Fit the corresponding double sided Velcro to one side or tip of the Relay cover

16.   Push the two crimps with two wires in them onto terminals 85 & 86. The polarity shouldn’t be important unless you’re using a different type of relay in which case it will be marked on the relay. The green striped wire from the harness is +ve

17.   Take a 425mm length of wire and crimp a 6.l3mm spade on one end

18.   Plug the spade from step 17 onto terminal 30 on the relay

19.   Plug the extended green striped wire from the turn signal onto terminal 87a on the relay

20.   Place the resistor and relay in place on the Velcro in the mirror housing taking care to ensure that the mirror hinge will not foul them when closed. Watch through the front of the assembly as you carefully close up the mirror into the housing.


21.   You should now be left with two unterminated wires. One from terminal 87a of the relay and one from the turn signal. Temporarily tape these two conductors together with some white PVC tape. (It’ll make the easier to find and fish out). Thread these into the area behind the headlight in readiness for terminating onto the parking light feed

22.   Repeat steps 1 – 20 above for the other side

23.   Remove the flat black plastic panel below the headlight assembly by removing the two 5mm allen bolts and pulling it forward gently.

24.   Carefully remove the connector to the temperature thermistor by pinching the clasp of the plug and pulling it away from the sensor.

25.   Remove the Parking Light by turning the housing ¼ turn and pulling gently down

26.   The space and available wire going to the Parking Light is limited. To this end, it is best to use Scotch Lock Crimps to tee into the two wired to provide two 100mm tails from the Parking Light

27.   Using solder and heat shrink, connect these two wires to the two pairs of wires from step 21 above. Trim the length of these pairs of wires whilst taking care to ensure that you have enough to work with

28.   Temporarily plug the Turn Signals onto their connectors

29.   Turn on the ignition and check that the parking light and both turn signals illuminate

30.   Using the turn signal switch, check that both left and right turn signals flash at the correct rate. You should also hear the relay clicking at the same cadence

31.   Next cancel the turn signals and check the Hazard Warning Lights (4-way flashers)

If you decide that you want to revert to Non Running Lights then just move the spade connector from terminal 87a to 87

The only technical downside to this project is that, should one of the front turn signal bulbs fail, the flash rate will not be affected. As standard, a bulb failure causes the flash rate to be twice as fast as way of a warning to the rider.

[Gar]

Tim, thanks for the detailed instructions.  It seems like quite a project. Have you ever heard of Skene Designs LED lights? They have a simple easily installed LED expandable control system module. On my bike I've attached front LED lights on the forks, rear LED brake lights on either side of the license plate and swapped out my turn signals for LED bulbs all connected to the control module. It's a super easy set-up with no soldering that any novice can do in about an hour and a half and provides a selection of very visible and super bright rapidly blinking lights that are hard to miss by any cager. 

[AZBob]

Thanks for posting. This is certainly an option for those who can perform this work.

Another option for those that are either lazy (such as myself) or don't have the skills/tools, there's a product called the Blinker Genie which is relatively cheap (I think they actually end up costing about the same as just the parts), tiny, and uses an IC rather than a mechanical relay, which means it will last infinitely longer (relays have a specified lifetime): http://www.customled.com/products/blinker-genie. I have these on my bike and they work flawlessly.

[tdragger]

Originally Posted by Gar

Tim, thanks for the detailed instructions.  It seems like quite a project. Have you ever heard of Skene Designs LED lights? They have a simple easily installed LED expandable control system module. On my bike I've attached front LED lights on the forks, rear LED brake lights on either side of the license plate and swapped out my turn signals for LED bulbs all connected to the control module. It's a super easy set-up with no soldering that any novice can do in about an hour and a half and provides a selection of very visible and super bright rapidly blinking lights that are hard to miss by any cager.

I am incredibly impressed with Tim's ingenuity.  I'm not quite the do-it-yourselfer as you so I have also gone with the Skene Design Photon Blaster system.  http://www.skenedesign.com/lights/PB_Features.shtml

[Tiny Tim]

Thanks for the replies. I've probably managed to make it seem a lot harder than it actually is!

The alternative units look interesting. Unfortunately, flashing lights can only be used for turn signals and for main beam flash (passing light) in the UK.

I fitted replacement LED bulbs but didn't find them as bright as the incandecent ones so I'm still on the lookout.

[Michel1960]

Originally Posted by AZBob

Thanks for posting. This is certainly an option for those who can perform this work.

Another option for those that are either lazy (such as myself) or don't have the skills/tools, there's a product called the Blinker Genie which is relatively cheap (I think they actually end up costing about the same as just the parts), tiny, and uses an IC rather than a mechanical relay, which means it will last infinitely longer (relays have a specified lifetime): http://www.customled.com/products/blinker-genie. I have these on my bike and they work flawlessly.

Hey Bob , did you use any of the recommended accessories or was it a straight install ?

[AZBob]

Originally Posted by Michel1960

Hey Bob , did you use any of the recommended accessories or was it a straight install ?

Biker Genie accessories? No, just the Genie(s) itself.

[Michel1960]

[quote
Biker Genie accessories? No, just the Genie(s) itself.
[/quote]

Thanks, part ordered!