3 prong electronic LED turn signal relay upgrade - Honda Rebel Forum
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post #1 of 17 Old 06-10-2018, 03:34 PM Thread Starter
 
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3 prong electronic LED turn signal relay upgrade

To upgrade the Honda motorcycles to LED turn signals, you first have to deal with the panel indicator light. It's wired as a bridge between the hot leads for both left and right turn signals. If you replace the turn signal bulbs with LEDs you get 4-way flashers if you don't rewire the indicator bulb circuit first. This is how I rewired mine with this flasher wired like this:



Remove the battery and air filter covers so that you can access and fish out the flasher relay. Remove the seats and gas tank so that you can run the new wire.




On the back side of the air filter box, inside the frame is the turn signal relay




Push it up to get its rubber loop off the hanger hook and feed it out the battery side.




Pull the 2 wires off the old relay and put them on the new relay, Battery to prong 49, lights to prong 49a



TEST your turn signals, if they flash correctly, proceed. If they stay steady on, swap the wires and test again.


(*10 image limit - continued in next post*)

2009 Honda Rebel 250
"The bravest thing for me to do is admit when I am wrong" - unknown
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post #2 of 17 Old 06-10-2018, 03:50 PM Thread Starter
 
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Remove the upper of the 2 bolts holding the headlight in place and pivot it down to get it out of your way. Remove the speedometer cable and tuck it out of your way. Remove the 2 screws for the junction box cover.



Use a female spade crimp-on connector with sheaf to connect a wire for the P prong to run to your panel.



Route it along the wire harness and up to the junction box, securing to the harness with electrician's tape and/or zip ties.
Locate the black 6 pin connector, this is the connector for the instrument lights. Find the panel side BLK/ORG and BLK/WHY wires, the harness side should have BLU and ORG wires.



Cut the orange and blue wires on the underside/harness-side of the connector (give yourself about an inch or a little more). Cap off the harness side of the ORG and BLU wires with electrician's tape so you don't get a short from them later on, and in case you later want to add something else to the turn signal circuits (such as a new spedo with separate left/right indicators, or extra turn signal lights)
Splice your new panel wire from the relay to one of the 2 wires, and splice a ground wire to the other. The panel bulb is incandescent so it doesn't matter which.




There is a 4 way bullet connector with all green wires, this is your ground that you need to connect to.
Acceptable: solder your ground wire to the 4-way ground connector. (tricky soldering, 4-way is a deep heat sink and pre-tin is essential)


Preferred:use 3.9mm metric motorcycle bullet connectors to make a splitter to connect your ground (I put in 2 since I plan to add passing lights soon)



(* continued next post *)

2009 Honda Rebel 250
"The bravest thing for me to do is admit when I am wrong" - unknown
HRF Answer #1 You should take the MSF Rider Course
HRF Answer #2 You need to clean your carburetor
HRF Answer #3 Sorry we assumed if you didn't say otherwise
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post #3 of 17 Old 06-10-2018, 03:58 PM Thread Starter
 
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TEST the turn signal lights, if you have good connections it will work.



If you flip the mounting L bracket that comes with the new relay you can re-use the rubber bit to re-hang the relay where it came from. It's a pain, frustrating, not enough room, takes small hands, skinny fingers and/or extra long gripping/manipulating tools to get it back on, but perseverance and imagination will prevail and you will eventually get it back in place!




TEST again to make sure you didn't knock one of the relay connectors loose when re-hanging.
Pack all the wires back into the junction box (careful and creative because its a tight fit) and reattach the cover.



TEST again to make sure you didn't disconnect one of your splices packing all that rat's nest into that little box.



Reconnect the speedometer cable, reattach the headlight, reinstall the tank, seats and side covers and you are ready to go shopping for your LED turn signals.

2009 Honda Rebel 250
"The bravest thing for me to do is admit when I am wrong" - unknown
HRF Answer #1 You should take the MSF Rider Course
HRF Answer #2 You need to clean your carburetor
HRF Answer #3 Sorry we assumed if you didn't say otherwise
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post #4 of 17 Old 06-10-2018, 04:11 PM
 
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Good writeup. Very clear instructions.
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2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
1973 Norton Interstate (in a box in the basement)
1968 Triumph Bonneville
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post #5 of 17 Old 06-10-2018, 04:21 PM Thread Starter
 
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Splices are made on the harness side of the instrument panel connector so that the connector can still be used to remove the instrument panel for fork maintenance.

It may be hard to see in the test pic after splicing the wires, but the indicator light is on and the right turn signal is on to show it works

My source for the flasher: https://www.superbrightleds.com/more...asher/780/834/

My source for the 3.9mm metric motorcycle bullet connectors. Other sources may list them as 3.8mm or 3.9/4.0mm, not to worry they are the same thing. Depending on the supply chain as to whether the male detente, male lug, or female connector was used to spec the part. https://www.amazon.com/gp/product/B01EREJYMY

And for the crimping tool for the connectors (worked great) https://www.amazon.com/gp/product/B00BQWO5RU

Butt splice connectors and wire were sourced from my local hardware store.
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2009 Honda Rebel 250
"The bravest thing for me to do is admit when I am wrong" - unknown
HRF Answer #1 You should take the MSF Rider Course
HRF Answer #2 You need to clean your carburetor
HRF Answer #3 Sorry we assumed if you didn't say otherwise
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post #6 of 17 Old 12-28-2018, 10:50 AM
haf
 
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I tried to do the same but unfortunately lights are not turn on..

I replaced all turn bulbs (No Led) with conventional lamps but the left or right (front, back) turn signals remains on steady.

Ok I understood that OEM flasher requires additional Amber...
Then I got this electronic flasher replacing the original..

https://store.ijdmtoy.com/12V-Electr...l-p/aa1192.htm

I connect the cables from OEM flasher to the new to B and E and from L I ran a new cable connecting the flasher indicator in the speedometer.

Then strange things happen... I move the turn switch to the left and ... the right lamps flashing fine!! When I move the switch on the right then a noise from the relay sounds like click -click-click continuously.

My questions.. is that led flasher compatible ? And where suppose i have to connect the cable that got from the L from flasher.

Sorry something I am missing here.







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1996 Honda CMX 250
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post #7 of 17 Old 01-02-2019, 07:47 PM
 
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Good write up!

I took a slightly different approach. I put in a "no load" 2 lug LED flasher (unplug original, plug in new) then I went up to the dash's turn signal indicator and soldered in two 12 volt silicon diodes (similar to what one would find in many rectifier circuits in a half wave rectifier configuration. That way when right turn signal is on the diode between the right side circuit and the left side (at the dash indicator) is reverse biased stopping any four way type action. Same is true in reverse when Left side is flashing to keep right side off the reverse biased diode works well and is a few cents cost to purchase (or little time to raid out of a broken and thrown out toy) I covered mine in heat shrink tubing after soldering them in and sealed them up well enough nothing unexpected could find the circuit conductor.

I kept my original front turn signal housing and modded LEDS in that housing for an original equipment look. Rear turn signals were replaced as I snapped off the original right rear in overzealous tightening (which started me on this mod. to begin with) I replaced both with a cool looking chrome bullet shaped turn signal from a vendor on Amazon. I found I needed to employ another Silicon diode in each to separate the running light circuit inside those bullet lights from the Turn signal circuit or else the running lights would have caused a similar problem to my turn signal system's correct functioning.

That was last winter. This winter I am supposed to replace remaining lighting with LEDS. I purchased an LED head light in the fall as the original type was dangerously dim just from age I guess. LOL I have not sat down and run the math on how much power is/will be saved but it is obviously already enough to run a small two-way radio should I ever want to. As you might can tell I am an inexperienced mechanic but I can find my way around a circuit board.

I'm just knockin' around on me 1986 CMX250C Honda Rebel
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post #8 of 17 Old 01-03-2019, 06:36 AM
haf
 
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Quote:
Originally Posted by StarBaseONE2 View Post
Good write up!

I took a slightly different approach. I put in a "no load" 2 lug LED flasher (unplug original, plug in new) then I went up to the dash's turn signal indicator and soldered in two 12 volt silicon diodes (similar to what one would find in many rectifier circuits in a half wave rectifier configuration. That way when right turn signal is on the diode between the right side circuit and the left side (at the dash indicator) is reverse biased stopping any four way type action. Same is true in reverse when Left side is flashing to keep right side off the reverse biased diode works well and is a few cents cost to purchase (or little time to raid out of a broken and thrown out toy) I covered mine in heat shrink tubing after soldering them in and sealed them up well enough nothing unexpected could find the circuit conductor.

I kept my original front turn signal housing and modded LEDS in that housing for an original equipment look. Rear turn signals were replaced as I snapped off the original right rear in overzealous tightening (which started me on this mod. to begin with) I replaced both with a cool looking chrome bullet shaped turn signal from a vendor on Amazon. I found I needed to employ another Silicon diode in each to separate the running light circuit inside those bullet lights from the Turn signal circuit or else the running lights would have caused a similar problem to my turn signal system's correct functioning.

That was last winter. This winter I am supposed to replace remaining lighting with LEDS. I purchased an LED head light in the fall as the original type was dangerously dim just from age I guess. LOL I have not sat down and run the math on how much power is/will be saved but it is obviously already enough to run a small two-way radio should I ever want to. As you might can tell I am an inexperienced mechanic but I can find my way around a circuit board.
Can you please provide a schematic ? I am still trying to figure out the same as the solution provided from Kryton don't work for me.. not sure is the flasher or something else...

thank you

1996 Honda CMX 250
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post #9 of 17 Old 01-03-2019, 08:36 AM
 
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The only thing Starbase did not mention in his writeup was the fact that when he added a forward biased diode in each of the existing wires going to the indicator lamp, he had to add a new ground wire to the bulb base side connection to allow the bulb to work properly.

The stock Honda flasher and indicator light setup depends on the characteristics of incandescent bulbs to work properly. With LEDs the whole system does not work without modifications.

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
1973 Norton Interstate (in a box in the basement)
1968 Triumph Bonneville
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post #10 of 17 Old 01-03-2019, 10:08 AM Thread Starter
 
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Quote:
Originally Posted by haf View Post
I tried to do the same but unfortunately lights are not turn on..
I replaced all turn bulbs (No Led) with conventional lamps but the left or right (front, back) turn signals remains on steady.
Ok I understood that OEM flasher requires additional Amber...
Then I got this electronic flasher replacing the original..
https://store.ijdmtoy.com/12V-Electr...l-p/aa1192.htm
I connect the cables from OEM flasher to the new to B and E and from L I ran a new cable connecting the flasher indicator in the speedometer.
Then strange things happen... I move the turn switch to the left and ... the right lamps flashing fine!! When I move the switch on the right then a noise from the relay sounds like click -click-click continuously.
My questions.. is that led flasher compatible ? And where suppose i have to connect the cable that got from the L from flasher.
Sorry something I am missing here.
Sent from my iPad using Tapatalk
@haf that flasher is not an in-line flasher and needs to be wired differently. B+ gets the 12v from the battery, E- has to get connected to ground. L goes to the lights that you want to flash. It does not have a separate connector for the panel light.

2009 Honda Rebel 250
"The bravest thing for me to do is admit when I am wrong" - unknown
HRF Answer #1 You should take the MSF Rider Course
HRF Answer #2 You need to clean your carburetor
HRF Answer #3 Sorry we assumed if you didn't say otherwise
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