Yamaha FZR 600 Mods: Custom LED Indicator Light Cluster

Radio Shack LED with Holder…

The Trail Tech Vapor sensors were installed on the Yamaha FZR 600, and ready to go.  The last step was to fabricate a mount and custom LED Indicator light cluster.  Easier said than done…

I ended up grabbing a piece of aluminum for the mount.  With Google SketchUp, I designed the layout, taking into account the distance from the top triple-tree past the ignition/key holder.  I left enough room for the custom LED Indicator light cluster, below where the digital gauge would be bolted.  Once designed, I printed out the template, taped it to the aluminum, and it was time to start cutting. A bit of grinding and use of the file made the edges smooth.  Ready for the install…

SketchUp Gauge Template

With the main sensor functions connected, the challenge was to figure out how to retrofit the bike with LEDs, in place of the stock incandescent bulbs.  Although Trail Tech sells an add-on indicator light Dashboard, which slips over the face of the gauge, it’s another $60, and I knew that I could fab something up with Radio Shack LEDs for about $10.  These old bikes don’t like LEDs, and it takes some finagling to get things right.

The key is to get some LED bulbs with the resistors build in.  Radio Shack has them for $2, and if you choose this type, the neutral, oil level and high-beam all work as you would imagine, without any hassle.  The trouble begins when wiring the turn signal indicator.  The way that old bikes with single turn signal indicators work is convoluted, and I will not try to explain it here (it would be an even LONGER post!).

What is needed for this install is a cheap (Radio Shack again, $2) pair of signal diodes.  These restrict the power flow to one direction, and are necessary on the turn signal indicator.  The directions are as follows:

Find the positive leads coming from the front turn indicators (colors vary by manufacturer).  Solder one signal diode to each wire, with the diode direction (typically indicated by a stripe) facing the indicator/dash bulb, to each of the 2 leads.  Solder the other ends of the 2 diodes together, making a “Y” connection.  Solder the single end of the Y connection to the positive (red) end of the dash bulb wire.  With the negative/ground (black) bulb wire, you need to tap into a ground.  On this bike, the high beam indicator has a ground wire (black), and I used a 2-into-1 bullet connector to complete the install.

Be sure to use a healthy amount of shrink-wrap, so that connections are not touching, and the diodes are securely wrapped and protected from the elements.  I took the advice of an online tutorial, and used small shrink wrap for the individual diodes and wires, and then larger shrink wrap to encase the entire diode connection.  Double safe for resisting (no pun intended) the weather.

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