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techtalk:ref:elec20 [2019/10/18 17:04]
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-====== REF: Electrical System ====== 
-====== Turn Signal Mods / Relocating ====== 
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-====== 86-90 LED Turn Signal Schematic ====== 
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-The stock turn signal blinker is 'load activated',​ meaning it requires a certain current draw before it functions correctly. 
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-If you change the TS bulbs to LED type, the stock blinker will not work (unless you use load equalizers). But, for these years, it is a simple matter replace the OEM Flasher with an LED-compatible Flasher, then add some diodes and ground wires to make the change. The following electrical diagram illustrates the needed changes. 
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-{{:​techtalk:​ref:​elec:​86-90-led-turnsignaldesign.jpg?​600|}} 
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-====== Front Turns on the Trees ====== 
-===== The vwclogan Front Turn Signal Mod ===== 
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-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_20_by_vwclogan.jpg?​direct&​300|}}| 
-|  2007 XL1200N ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2)) ​ | 
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-|Tools include a hacksaw, file and a drill. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|1/​4"​ steel tubing, black 1/4" PVC tubing or a \\ bunch of washers can used for spacers. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453)) ((http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=5))| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2_by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_4_by_vwclogan.jpg?​direct&​300|}}| 
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-|Template for the bracket. \\ Entire drawing should print out 2" x 2". \\ (notched to get around a small edge in the tree) ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))|Holes drilled in 3/4" wide bracket. \\ Left hole (tree) - 3/8". Right hole (turn) 5/16". ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_6_by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3_by_vwclogan.jpg?​direct&​300|}}| 
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-|Parts: (2) 5/​16"​x24x1-1/​2"​ bolt, lockwashers and spacers. ((photos by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_5_by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_1_by_vwclogan.jpg?​direct&​300|}}| 
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-|Remove the lower tree bolt on the right side. ((photo by vwclogan of the XLFORUM, resized/​cropped by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))|Remove the rounded bolt from the signal with an \\ Allen wrench. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_8._by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_9_by_vwclogan.jpg?​direct&​300|}}| 
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-|Mount the new bracket to the tree. Torque the existing bolt (#45 Torx socket head) to 30-35 ft lbs. ((photos by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2)) ((http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=6))||Add a spacer on a bolt to extend the turn housing. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_10_by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_11_by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_13_by_vwclogan.jpg?​direct&​300|}}| 
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-|Tighten the turn and zip tie the wires nice and neat. ((photos by vwclogan of the XLFORUM, resized/​cropped by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))||Reposition as needed and start on the other side. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_14_by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_15._by_vwclogan.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_16_by_vwclogan.jpg?​direct&​300|}}| 
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-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_18_by_vwclogan.jpg?​direct&​300|}}| 
-|  After / Before \\ Stock front turns on a 2007 XL1200N ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2)) ​ | 
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-==== Alternate Bracket Material ==== 
-|  Bracket made from aluminum flat bar ((photos by Matt.loup.t of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ || 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_1_by_matt.loup.t.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2_by_matt.loup.t.jpg?​direct&​300|}}| 
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-|These rectangular strips were bought from a hardware store. They are size 3 (CHGO NO 3) and the holes are 1" apart (center to center). \\ You can also find stainless spacers in the correct size. Cut and shape the brackets, over drill one hole on each, paint them. ((photos by DedPyro of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11))||| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_1._by_dedpyro.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2._by_dedpyro.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3._by_dedpyro.jpg?​direct&​300|}}| 
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-|Use the original signal mounts, some flat metal stock and a bolt with the same thread as mirrors. Cut the stock to size and drill the 3/8" holes for the tree mount. ((photos by dieselbikin of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=10))||| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_1_by_dieselbikin.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2_by_dieselbikin.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3_by_dieselbikin.jpg?​direct&​300|}}| 
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-|**Modification for 48'​s**. The only difference is that you need to drill two 3/8" holes in both brackets and angle the brackets from the tree \\ slightly to allow the nut to clear. The 48 turn signal has the wires running through the mounting stud rather than having them come out the back of the housing. \\ The mounting stud is the perfect length to fit the new 1" spacer and there is ample room to bolt the original nut and lock washer to the new bracket. ((photos by ccain of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11))||| 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_1_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3_by_ccain.jpg?​direct&​300|}}| 
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-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_6_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_7_by_ccain.jpg?​direct&​300|}}| 
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-|All thread coupling: In the first pic below, the top 2 fasteners were removed from each side and discarded; (L) 3/8" x 18 pinch bolt and (R) turn signal stud. \\ The 2-1/4" threaded rod and coupling nut replaces the pinch bolt and provides for more threads in the tree. 3/8" rods can be cut from all-thread or a 5" carriage bolt. \\ The coupling nuts are 1-3/4" long or can be cut shorter (these were cut to 7/8"). The signal stud is replaced with a 5/16" x 24 bolt with the head ground down just \\ enough to fit inside the coupling nut snugly. It is then cut so there is about 1/2" of threads to screw into the turn signal housing with a jam nut threaded on it. \\ The carriage end of the 5/16" bolt is then inserted into the coupling that has been side drilled and tapped for a #10x32 set screw to hold the signal bolt tight. ​ \\ The tree can be torqued back properly by use of a crows foot on a socket wrench applied to the coupling. ((photos by alank of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=438111&​page=2))||| 
-|{{techtalk:​ref:​svcproc:​turn_signal_relocation_1_by_alank.jpg?​direct&​300|}}|{{techtalk:​ref:​svcproc:​turn_signal_relocation_2_by_alank.jpg?​direct&​300|}}|{{techtalk:​ref:​svcproc:​turn_signal_relocation_3_by_alank.jpg?​direct&​300|}}| 
-==== Bikes with this mod ==== 
-**Mounted to lower trees**: 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_by_byumetalman.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2_by_privation.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_by_gillespk.jpg?​direct&​300|}}| 
-|  2012 883N ((photo by byumetalman of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=10)) ​ |  2009 XL1200N ((photo by privation of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=4)) ​ |  2007 883L ((photo by Gillespk of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=9)) ​ | 
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-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_5_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3_by_matt.loup.t.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_4_by_dedpyro.jpg?​direct&​300|}}| 
-|  2012 XL1200X ​ ((photo by ccain of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ |  2012 XL1200C ((photo by Matt.loup.t of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ |  2007 XL1200R ((photo by DedPyro of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ | 
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-**Mounted to upper trees**: 
-|{{:​techtalk:​ref:​elec:​turn_signal_relocation_4_by_dieselbikin.jpg?​direct&​300|}}| 
-|  2000 XL1200 ((photo by dieselbikin of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=10)) ​ | 
-====== Front Turns on the Forks ====== 
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-|98 1200C \\ Turns mounted with electrical conduit clamps. ((photo by jacobbuelow of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|09 883L \\ Turns mounted with electrical conduit clamps. ((photo by rockmanbm of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=7))| 
-|{{:​techtalk:​ref:​elec:​fork_clamps_by_jacobbuelow.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​fork_clamps_by_rockmanbm.jpg?​direct&​300|}}| 
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-====== Rear Turns ====== 
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-===== Loose Rear Turn Signal - Fixes ===== 
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-Some times the double-ended stud that mounts the rear turn signal housing to the fender (thru a stand-off spacer) is not long enough to get a good bite on the threads in the housing. That eventually leads to the first few threads stripping out. Even though there are more threads in the housing, the stud will not reach deep enough. 
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-Note that on some of the stock studs, the housing threads on the double-ended stud have a different pitch than the fender mounting threads. 
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-SportyTrace suggested the following: ((http://​xlforum.net/​forums/​showthread.php?​t=2072073))\\ 
-I ended up fabbing up a replacement longer threaded stud that could get deeper into the indicator body to use the good remaining threads. I used all-thread rod. The trick was getting a nut fixed into place on threaded rod and making the stalk the correct length. I ended up purposely messing up the threads at the fixing point and added loctite too. Worked a treat, but was a bit fiddly. Shown below: original stock one on top and home-made replacement beneath.\\ 
-{{:​techtalk:​ref:​elec:​turnsignal-rearmtgstud-diy.jpg?​400|}} 
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-The threads may be repairable using JB Weld (lightly coating the inside of the hole), then rethreading the housing. If all the threads in the housing are stripped, using the above extended stud might reach far enough to use a nut (or speed nut) on the inside of the housing. ​ 
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