{"id":620,"date":"2020-07-14T03:03:58","date_gmt":"2020-07-14T03:03:58","guid":{"rendered":"https:\/\/advwisdom.com\/a\/?p=620"},"modified":"2020-07-14T03:03:58","modified_gmt":"2020-07-14T03:03:58","slug":"klr-diy-led-aux-lights","status":"publish","type":"post","link":"https:\/\/advwisdom.com\/a\/klr-diy-led-aux-lights\/","title":{"rendered":"KLR DIY LED Aux Lights"},"content":{"rendered":"
Homemade LED Auxiliary Lights for the KLR650 DIY<\/strong><\/div>\n
\n
Enclosed are the step by step instructions I used to make custom LED auxiliary\/running lights. The intent of the lights are to supplement the KLR650 headlight. The advantages of this lighting system are:
\n1. Bight lights = increased visibility. A safety issue
\n2. 2x additional forward facing bright lights gives other drivers a depth perseption in judging your distance relative to their location.
\n3. LED\ufffds are very vibration resistant, never burn out, and are low power consumption. The ones I selected are the brightest I could find within a 1 inch diameter cluster. This system consumes 5.4 watts total!
\nNote: No LED auxiliary lights are commercially available, so I was forced to make my own. There are 4x phases of this install.
\n1. LED bulb evaluation.
\n2. Light attach bracket to KLR650 (fellow KLRworld Mark was the inspiration for my design).
\n3. LED bulb attach to light housing.
\n4. Wiring to bike.
\nThe Bracket material was 6061-T6 at .10 inches thick. It can be found here for $11.87, all you need is a 12 inch x 12 inch size:
\nhttp:\/\/www.onlinemetals.com\/merchant…owunits=inches<\/a>
\nThe LED\ufffds can be found on E-bay here for $13.50 each:
\nhttp:\/\/cgi.ebay.com\/ebaymotors\/WHITE-24-LED-replacement-bulb-lamp-light-s-with-wires_W0QQcmdZViewItemQQcategoryZ35598QQihZ010QQit emZ200061654414<\/a>
\nThe auxillary lights can also be found on E-bay here for $14.99
\nhttp:\/\/cgi.ebay.com\/ebaymotors\/3-in-CLEAR-HALOGEN-ROUND-FOG-DRIVING-LIGHTS-NEW-AB_W0QQcmdZViewItemQQcategoryZ6755QQihZ013QQitemZ2 30090466726<\/a>
\nThe cost of the modification costs about $54 total!
\n\"\"
\nstart all projects by reviewing topic
\n\"\"
\nlight bracket overall size 12 inch x 7 inch
\n\"\"
\nremove front fender
\n\"\"
\nmeasure attach bracket pad \ufffdland\ufffd size
\n\"\"
\ngross trim iteration 1.
\n\"\"
\nafter the band saw<\/p>\n

\"\"
\ncheck placement
\n\"\"
\ntrim again
\n\"\"
\nmark again
\n\"\"
\ntrim again
\n\"\"
\nlocate attach holes, this bracket will be part of the fender stack-up
\n\"\"
\ndrill here
\n\"\"
\ncheck hole size
\n\"\"
\ndrill and deburr
\n\"\"
\ntime to place back on bike
\n\"\"
\ncheck clearance. Does not hit the nerf bars! That\ufffds good.
\n\"\"
\nlight will be mounted about here
\n\"\"
\nthis is the light to mount. This one came with a 55 watt H3 type bulb. I replaced the as delivered bulbs with these 35 watt bulbs
\n\"\"
\nneed this 12 volt DC source for testing. It actually puts out 14 volts.
\n\"\"
\namp and volt meter
\n\"\"
\nshrink wrap kit
\n\"\"
\nwire connector kit
\n\"\"
\n35 watt H3 bulb output
\n\"\"
\nmeasured output = 3.016 amps or 42 watts
\n\"\"
\nThis is the LED I\ufffdll be swapping out for that H3 incandescent bulb.
\n\"\"
\nmeasured output =.192 amps or 2.7 watts per bulb
\n\"\"
\nbulb diameter = 1.034 inch
\n\"\"
\nwill fit the bulb deep and securely in this light housing
\n\"\"
\nside by side . Small LED flashlight, normal 2 D cell flashlight, 12 volt LED light, and 35 watt H3 bulb.
\n\"\"
\nLED has cluster lights shining to the side
\n\"\"
\nmeasure small diameter = .577 inches
\n\"\"
\npower-up the LED\ufffds. very bright and cool to the touch
\n\"\"
\nlight from rear
\n\"\"
\nneed to attach(glue) this plastic washer to the LED\ufffds
\n\"\"
\nwasher size outer diameter = 1.258 inch. Can get at Home Depot
\n\"\"
\nmeasure and trace
\n\"\"
\nbest to hand file to the marking
\n\"\"
\npress fit on the LED\ufffds
\n\"\"
\nneed to attach some of this reflector tape to those washers
\n\"\"
\ntrace and cut
\n\"\"
\nattach to LED
\n\"\"
\nglue on
\n\"\"
\ndisassemble these new lights
\n\"\"
\nlike so
\n\"\"
\nmark trim line
\n\"\"
\nwill fit LED deep in here
\n\"\"
\nready for cutting\/trimming
\n\"\"
\nsince the metal is so thin, best to route to trim line. Drill will thrash the housing. Spotface won\ufffdt work either.
\n\"\"
\nslowly open-up the hole
\n\"\"
\nblow out particles collected
\n\"\"
\nnice centered hole to accept the LED bulb
\n\"\"
\ncenter LED bulb in hole
\n\"\"
\ntape in place. Note: I destroyed a light housing in an earlier attempt at this project by gluing the bulb in place at this step. The fumes given off while the glue is curing got into the reflector area and stuck to the reflector and glass. This made the reflector \ufffddull\ufffd. Tape works fine. Although not clearly shown it is fully taped up and sealed.
\n\"\"
\nlike in this view
\n\"\"
\nthe LED bulb extends far into the light housing and is secure
\n\"\"
\nanother view
\n\"\"
\nremove the baseplate for trimming
\n\"\"
\nwant it flush up to the bracket
\n\"\"
\nmeasure and mark. Need to take a little off the edge
\n\"\"
\ntrim
\n\"\"
\nsand
\n\"\"
\ntad bit off the end
\n\"\"
\nre-assemble. Note: I reversed the light bracket to the rear
\n\"\"
\nwill fit like this
\n\"\"
\nfinal bracket trimming required
\n\"\"
\nmark trim lines
\n\"\"
\nband saw trim
\n\"\"
\ndisc sanding trim
\n\"\"
\nlight attach holes
\n\"\"
\ndrill, deburr, and countersink
\n\"\"
\nquick check on fender
\n\"\"
\nattach on bike
\n\"\"
\nadjustable sturdy and robust design
\n\"\"
\ncheck clearance. No issues
\n\"\"
\nA-OK here too!
\n\"\"
\nmake wire connectors. White = 12v ground. Black and Red = 12v +
\n\"\"
\ncrimp and shrink wrap
\n\"\"
\nUsing this on all electrical connects to keep water out of the connections
\n\"\"
\nlight wiring all done
\n\"\"
\nview of system with no power
\n\"\"
\nwire connection in faring. No binding issues when turning handle bar
\n\"\"
\nthe bike side connection is covered here \ufffdKLR650 Marker lights install and review\ufffd:
\nhttp:\/\/klrworld.com\/forums\/index.php\/topic,1956.0.html<\/a>
\nI\ufffdm basically tapping into the city light leads in the front faring.
\n\"\"
\nfire up the lights!
\n\"\"
\nwith headlight on
\n\"\"
\nclose up of LED light
\n\"\"
\noff centerline view
\n\"\"
\nlights off
\n\"\"
\n1\/4 view lights off
\n\"\"
\nforward view lights on
\n\"\"
\n1\/4 view lights on. Note small marker light on faring
\n\"\"
\nanother view
\n\"\"
\nwith camera filter
\n\"\"
\noff front view
\nReview of Mod.
\n1. Very bright system. I\ufffdll leave them on always.
\n2. Low power consumption 5.4 watts total.
\n3. Low cost modification $54 total
\n4. Light system will outlast the bike
\nIn summary I\ufffdm very pleased with the project outcome, It exceeded my expectations.<\/div>\n","protected":false},"excerpt":{"rendered":"

Homemade LED Auxiliary Lights for the KLR650 DIY Enclosed are the step by step instructions I used to make custom LED auxiliary\/running lights. The intent of the lights are to supplement the KLR650 headlight. The advantages of this lighting system are: 1. Bight lights = increased visibility. A safety issue 2. 2x additional forward facing […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[],"tags":[],"_links":{"self":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/620"}],"collection":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/comments?post=620"}],"version-history":[{"count":1,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/620\/revisions"}],"predecessor-version":[{"id":621,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/620\/revisions\/621"}],"wp:attachment":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/media?parent=620"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/categories?post=620"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/tags?post=620"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}