KPX 200 Turn Signal Wiring Diagram

[ecabo]

I got this bike last summer that didn't come wired for turn signals although it did have a turn signal switch on the handle bar. I wrote something about it here on CR last June. I haven't had the income to purchase an enduro lighting kit. I want to ride it starting this summer and this is what I have in the way of parts for the turn signals:

1. Turn signal switch with 1 orange, 1 gray and 1 light blue wire coming out of it

2. Set of 4 turn signals with 1 black wire and 1 yellow wire coming out of each turn signal

3. Two prong flasher relay

I figure I'll buy bulk wiring -- strand of orange, light blue, black, and red wires -- and various connectors from the auto parts store to connect it all.

In the meantime I have been researching how to wire everthing together and drew up this wiring diagram. Sorry, I don't know how to do a proper schematic nor do I know how to read them. The left-most column shows the turn signal switch on the top, flasher relay in the middle and battery on the bottom. Can someone tell me if this is the correct way to wire the turn signals?

http://farm6.static.flickr.com/5141/5673891719_42552291be_z.jpg (http://www.flickr.com/photos/cabomediagroup/5673891719/)
lighting diagram for chinariders (http://www.flickr.com/photos/cabomediagroup/5673891719/) by ecabo3 (http://www.flickr.com/people/cabomediagroup/), on Flickr

[SpudRider]

I must admit, I frequently have trouble following the maze of lines in a motorcycle wiring diagram. ;)

However, your circuit looks correct to me, Ecabo. :) Obviously, you aren't concerned with including a turn signal indicator, so that simplifies the wiring. :) I think you should probably include a 10A fuse between the battery and the flasher relay. ;)

I hope others will also offer their advice regarding this matter. I have been known to make errors concerning wiring diagrams. ;)

Spud :)

[ecabo]

UPDATE

I wired my turn signals and they work great! It felt good to see them blink to life for the very first time. I wanted to post the final wiring diagram I used and some pictures of the finished work. One thing I did not know to do at the time is wire into the ignition key. This means that I can operate the turn signals without turning on the key. I'm not sure if I like that or not. Time will tell.

I'm on a tight budget so purchasing an enduro kit was not an option for me. Instead, I purchased the following:
turn signals
2 prong turn signal relay ($4 from Autozone)
10 amp in-line fuse
16 gauge primary wire - red (for battery)
16 gauge primary wire - black (for ground and power supply)
16 gauge primary wire - orange (for left turn signal)
16 gauge primary wire - light blue (for right turn signal)
cable housing (to make it all look nice)
1/4 inch round terminal connector (for battery and ground)
butt connectors (for in-line fuse)
bullet connectors
wire taps
shrink tubing

Here is the final diagram
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/lighting%20diagram%20for%20chinariders%202.jpg

Decided to put the turn signal relay under the seat after checking for clearance
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2303.JPG

Took Spuds advice and put a 10 amp in-line fuse between the battery and relay
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2305.JPG

After hooking up the battery wire I started to connect the rear turn signals
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2302.JPG

All the turn signals must be grounded to the bike. I chose one grounding point at the rear of the bike -- underneath the seat and just behind the relay
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2301.JPG

This is what the wiring in the rear looks like
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2310.JPG

Ran the orange, light blue and black wires to the front of the bike. Here is the rat nest behind the headlight
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2306.JPG

Up front I had to take the wires coming out of the turn signal control switch and the wires coming from the turn signal indicator lamp (good thing they have the same color codes) and connect them to the orange and light blue wires coming from the rear of the bike. There is also a gray wire coming from the turn signal control switch -- this is the OFF position for the turn signals. Connect the gray wire to the black wire coming from the turn signal relay.
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2307.JPG

As mentioned earlier, all turn signals must be grounded. I tried to ground the front turn signals somewhere up front, but too many mistakes with my crimping left me short on terminals. Working with what I had, I decided to join the two grounding wires together and run a single wire to the rear of the bike and ground it there. Not the neatest, but I was satisfied with it
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2308.JPG

Somewhere hidden within the cable housing I used to keep things looking somewhat orderly are two wire taps. I'm sorry I didn't take a picture of it. The wire taps were used to connect the turn signal indicator lamps, turn signal control switch and the front turn signal lights to the single orange and light blue wires coming from the rear. I hope the wiring diagram can illustrate how I hooked that up.

This is how I routed the wires. I went down the right side of the frame instead of the left because the left was already full of wires. Using cable housing keeps things looking neat
http://dl.dropbox.com/u/31120585/Motorcycle%20Turn%20Signals/CIMG2309.JPG

This was a fun project and I learned a lot from it. If I had to do it again I would:
Connect the turn signal switch to the ignition
Buy gray primary wire to connect to the signal OFF switch
Ground the front turn signals somewhere up front so as not to have a single grounding point
Have all manner of extra terminals and connectors

I'm working on removing rust from the inside of my gas tank... but that's another story.

[Weldangrind]

Thanks for an excellent report! :D Unfortunately, all I'm getting are the dreaded red X's where pics should be.

Regarding the gas tank, I had excellent luck with a liquid calcium / lime / rust remover that is typically used in plumbing applications. I removed the tank, closed the valve, used a dirt bike fuel cap with a vent (so I could plug it with a rubber cap) and poured the chemical in. I then tossed in a handful of stainless wood screws as an abrasive. Over the next week, I went out to the shop and shook the tank vigorously a couple times a day, making sure to position it agains the wall a different way each time, so as to allow the chemical to sit on a different surface of the tank. I used about two quarts of chemical with a quart of water for a strong solution, and it worked great.

Upon pouring the liquid out the next week, I had a nice, shiny and (mostly) rust-free tank. Mine was extremely bad to begin with, having sat outside for 25 years. I rinsed it with plenty of water, dried it with the exhaust of my shop vac and filled it with fuel. Done.

[ecabo]

Whoops! Thanks Weldandgrind. I fixed the problem with my picture links and the images should be showing up now.

Also, thanks for your tip on getting rid of rust from the tank. I'll start another thread showing the results after the weekend.

[SpudRider]

You did a super job, Ecabo! Thank you for you documenting your excellent post with great photographs! :D

Spud :)

[Weldangrind]

Wow! Excellent detail!

Your report is very timely, because I'm struggling with a new turn signal switch for a bike with no wire at all. I spent a couple of hours with a multimeter and figured out which wires control the high / low beam, signals and horn. All that's left is everything else.