{"id":685,"date":"2020-07-14T03:11:57","date_gmt":"2020-07-14T03:11:57","guid":{"rendered":"https:\/\/advwisdom.com\/a\/?p=685"},"modified":"2020-07-14T03:11:57","modified_gmt":"2020-07-14T03:11:57","slug":"klr-led-tail-light-mod","status":"publish","type":"post","link":"https:\/\/advwisdom.com\/a\/klr-led-tail-light-mod\/","title":{"rendered":"KLR LED Tail Light Mod"},"content":{"rendered":"
KLR650 LED tail light system install and review<\/strong><\/div>\n
\n
Enclosed is a step by step procedure for replacing the stock 1157 tail light with a modern, low power consumption, bright LED replacement. I will also supplement the tail light with an aftermarket LED Light Bar. The advantages of the modification are as follows:
\n1. Long live bulbs. The bulbs will outlast the bike. Even the KLR!
\n2. No more bulb replacement
\n3. Low power consumption system
\n4. Brighter system
\n4. Vibration\/shock resistant bulbs
\n5. More visibility = less likelihood of rear end collision
\nThe inspriation for this modification is based on a thread by fellow KLRworld members including kramsetac, 75,000 miles, Quarterhorse 2, and \ufffdspecial adult\ufffd Bikerscout.
\nThe LED\ufffds can be found at www.customdynamics.com<\/a> The reflector tape can be found at any autoparts store in the near the paint supplies. LED Items to install:
\n1. 1157 tail\/stop light LED replacement Radiant cluster 1.85 inch red Direct base Get SKU # 5302-19 for $34.99
\n2. 6 inch lightbar – red\/black SKU 02010 $35.95
\n\"\"
\nbrushup on KLR650 electrical\/wire issues
\n\"\"
\nItems to be installed
\n\"\"
\nLED 1157 tail light, Plug in existing socket
\n\"\"
\n6 inch tail\/stop light supplement. Not a tail light replacement. Will need to mount and wire this item
\n\"\"
\ninstall instructions
\n\"\"
\nreflector tape. Metallica…Rock on Man…”FreeBird”!!! hehehe
\n\"\"
\nremove tail light plastic housing
\n\"\"
\nexposed bulb and \ufffddull\ufffd reflector
\n\"\"
\nstock bulb and LED replacement
\n\"\"
\nbackside view
\n\"\"
\ninstall LED in socket. Just push while turning. May need to rotate 180 degrees when installing. Will only engage correctly one way
\n\"\"
\nall installed, No issues fits fine
\n\"\"
\nneed to remove the housing reflector to make it mirror like finish. Remove these 2x nuts 10mm wrench
\n\"\"
\nunhook wires 3x total. Just pull while turning. Don\ufffdt worry it won\ufffdt brake. I added tape so I know to reconnect the correct wires together
\n\"\"
\n2x nuts off, 3x wires labeled and disconnected
\n\"\"
\nreflector can now be removed
\n\"\"
\nnow apply that mirror sticky side tape
\n\"\"
\nunroll the 6 foot long tape, cut 1 foot or so.
\n\"\"
\nthe housing is symmetric so you can work from the paper side
\n\"\"
\ntrim to fit
\n\"\"
\npeel back the paper exposing the adheasive
\n\"\"
\ninlay on the plastic reflector….No worries about heat from LED\ufffds. There is none!
\n\"\"
\nmirror like reflection…see the camera?
\n\"\"
\nnow the sides
\n\"\"
\nmark trim lines
\n\"\"
\ninlay to check
\n\"\"
\ntape opposite side
\n\"\"
\nlike so!
\n\"\"
\nback side now. Since it is curved it will have to be installed piecemeal
\n\"\"
\ncover screw studs
\n\"\"
\ndrape the material as best you can
\n\"\"
\nalmost done
\n\"\"
\ncheck bulb does not contact material
\n\"\"
\ncheck power consumption
\n\"\"
\nStock bulb tail light only .446 amps or 6.24 watts of power
\n\"\"
\nStock bulb Brake light only 1.903 amps or 27 watts of power
\n\"\"
\nNew LED tail light only .070 amps or 1.0 watts of power
\n\"\"
\nNew LED Brake light only .354 amps or 5 watts of power
\nThe LED consume ~ 17% of the stock wattage. Woohoo!
\n\"\"
\nlight bar tail on at .020 amps or .24 watts
\n\"\"
\nlight bar Brake light at .25 amps or 3.0 watts
\n\"\"
\nneed to make 3x of these electrical splice\/spliters to run power to LED light bar
\n\"\"
\nwill attach here
\n\"\"
\nlike so. Each one is color coded. Look at Stebel horn install for walk thru of making a wire bundle
\n\"\"
\nreattach the tail light housing
\nadd LED bulb
\n\"\"
\nthread wires thru opening
\n\"\"
\nattach color coded wire bundles
\n\"\"
\nawaiting to attach to LED bar
\n\"\"
\nmake and attach LED bracket, use this Aluminum angle
\n\"\"
\ntrace outline
\n\"\"
\nmark cutting trim lines
\n\"\"
\nafter bandsaw cut
\n\"\"
\nwill attach bracket here, measure hole pitch
\n\"\"
\ntransfer measurements
\n\"\"
\ntrim bracket with band saw
\n\"\"
\nquick check to see if fits ok
\n\"\"
\ndrill mounting holes in bracket tabs
\n\"\"
\ndrilled and deburr holes
\n\"\"
\ncheck fit
\n\"\"
\nmount light bar here
\n\"\"
\nuse rubber gasket as template
\n\"\"
\nmark holes
\n\"\"
\nattach bar to bracket with metric M4-.7 allen head bolts
\n\"\"
\ncheck drill size
\n\"\"
\ndrill and deburr
\n\"\"
\nready to mount
\n\"\"
\nthread wire thru center access hole
\n\"\"
\nuse loctite on threads
\n\"\"
\nlooks good!
\n\"\"
\nready to mount on bike
\n\"\"
\npickup these 2x holes
\n\"\"
\ndrill small hole to thread wires under fender
\n\"\"
\nmounting complete
\n\"\"
\nwires threaded thru here
\n\"\"
\nstandoff view lights off
\n\"\"
\nwires to connect to splicer
\n\"\"
\nwire splice tools ready!
\n\"\"
\ncut excess length
\n\"\"
\nstrip insulation
\n\"\"
\nadd 1x small shrink wrap (white) + 1x large shrink wrap (black) + one waterproof 20 AWG wire crimp connector
\n\"\"
\ncrimp connector
\n\"\"
\nshrink wrap connectors
\n\"\"
\nrepeat all 3x connectors
\n\"\"
\nzip tie the wires to frame…now for the results……
\n\"\"
\nOEM stock tail bulb tail light only (no brake)
\n\"\"
\nLED tail light (no brake)
\n\"\"
\nOEM stock brake light
\n\"\"
\nLED brake
\n\"\"
\nLED tail
\n\"\"
\nLED brake
\nReview:
\nI think the system exceeded my expectations
\n1. Low power consumption LED use ~ 20% of incandescent power (6.24 watts vs. 1.24 watts LED) for tail light and (27 watts vs. 8 watts) for brake light.
\n2. Recommend adding the reflective material
\n3. Vibration resistant system.
\n4 Much brighter than stock. Nice safety issue! Especially if viewed from directly behind.
\n5. Independent Fail-safe light system.
\nHappy with mod<\/p>\n

I have also designed a custom 5.5 watt LED superbright fog lights. See below:
\n\"\"
\n1\/4 view lights off
\n\"\"
\nforward view lights on
\n\"\"
\nwith camera filter<\/div>\n","protected":false},"excerpt":{"rendered":"

KLR650 LED tail light system install and review Enclosed is a step by step procedure for replacing the stock 1157 tail light with a modern, low power consumption, bright LED replacement. I will also supplement the tail light with an aftermarket LED Light Bar. The advantages of the modification are as follows: 1. Long live […]<\/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\/685"}],"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=685"}],"version-history":[{"count":1,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/685\/revisions"}],"predecessor-version":[{"id":686,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/685\/revisions\/686"}],"wp:attachment":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/media?parent=685"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/categories?post=685"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/tags?post=685"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}