Need some info on home built Dual Sport Kit.....


43 replies to this topic
  • Zadok

Posted February 11, 2009 - 05:22 PM

#1

Well guys, and gals, Im looking into the possibility of making my WR450F
street legal for DS riding. HighFive has some nice little trips planned that
Im a bit interested in being a part of....:worthy:
So I need some help from those of you in the know. I dont want an "off
the shelf" kit. I just havent seen one that I really like completely.
So here is what I want to do:

2009 WR450F

Use these Switch housings (which will be used for turn signal left/right,
starter button, and kill switch. I will used my existing kill switch button
for the horn)
Posted Image

Use these LED strips, custom set into my headlight nacelle, as turnsignals.
I will also use something similar in clear as my license plate light.
Posted Image

Use this Banjo Brakeline switch to activate the tail light
Posted Image

I want to mount the license plate using heavy rubber, probably from
a tire. That way it will easily flex if (no make that when) I loop out etc.

So what I want to know is,

how would I go about wiring the switches up
to the turn signals? Do I need to install some type of seperate fuse etc?

can I, and how, do I use the existing tail light as a running and brake light?
or will I need to get a different light?

Any info you may have to help would be greatly appreciated.
So what do you guys think.....Pretty good setup eh? I think it will be.
Very "off road" capable. No turn signals to break, no license bracket
to break etc.:lol:

  • motomanny

Posted February 11, 2009 - 06:19 PM

#2

How much are you thinking you will end up spending? The reason I ask is because (I know you dont want an off the shelf kit) there is a kit available that is the best I've seen out there from a company called sicass racing, with the all LED upgrade its about $430.00 but it is turn key......no wires to cut, everything plugs right in and is very easy to install. I have one on my 08 wr450 and it looks and works awesome!

  • Zadok

Posted February 11, 2009 - 06:53 PM

#3

I will have under 200 bucks into the set up. Ill look into the kit
you are talking about though. I just like the simple switches I
have picked out, as well as the simple design of using heavy
rubber as a license plate mount.

  • motomanny

Posted February 11, 2009 - 08:17 PM

#4

Well you can probably buy anything you might need in seperate parts such a 2 element tail light that will bolt right up, horn and any applicable relays and probably a flasher element too.......im not affiliated with them at all but I was completely satisfied and impressed with their products, and the guy there was very helpfull and seemed to know his stuff. I'm sure he could answer your question about the signal and what you need to make that work. I think the guys name is Mike, you can google the company for the website and phone number. Good luck! P.S if you want to see the end result on a WR I have pictures I can e-mail you.

  • Birdy426

Posted February 11, 2009 - 11:51 PM

#5

A question before we can provide too much help...what year WR aqre we talking about? A 400/426 with no battery or a 450 with a bat? For the former, you need to float the lighting coil and replace the stock regulator with a regulator/rectifier to make DC. For the latter, I think you can leave the lights AC, run the turn signals and hord off the battery and be fine...can any 450 riders verify?

What do you plan to do for rear turn signals?

Though those switches are pretty bitchin', using 2 separate switches for your turn signals may prove problematic...you will need to use a "3 prong" flasher...power comes in on one leg and leaves on both others...pretty simple to wire, from the flasher to the switch to the turn signals (front and read on the same side) and then to ground. But unless you are running an incandescant bulb in the rear, you need a special flasher to drive the LEDs. (there's not enough resistance in an LED system to make a bimetal flasher work) I've never seen one of those in a 3 prong config.

As far as the tail/stop light, the stock light is already a 2 filament bulb and socket. There is another wire burried in the harness under the seat that connects to the second (brake light) filament. Run power from the bat to the brake switch to the brake light wire, and you're done.

Horn is easy, too. Power to the switch, switch to the horn, and horn to ground.

Good luck, and post up some pics when you're done!

  • Zadok

Posted February 12, 2009 - 05:29 AM

#6

A question before we can provide too much help...what year WR aqre we talking about? A 400/426 with no battery or a 450 with a bat? For the former, you need to float the lighting coil and replace the stock regulator with a regulator/rectifier to make DC. For the latter, I think you can leave the lights AC, run the turn signals and hord off the battery and be fine...can any 450 riders verify?

What do you plan to do for rear turn signals?

Though those switches are pretty bitchin', using 2 separate switches for your turn signals may prove problematic...you will need to use a "3 prong" flasher...power comes in on one leg and leaves on both others...pretty simple to wire, from the flasher to the switch to the turn signals (front and read on the same side) and then to ground. But unless you are running an incandescant bulb in the rear, you need a special flasher to drive the LEDs. (there's not enough resistance in an LED system to make a bimetal flasher work) I've never seen one of those in a 3 prong config.

As far as the tail/stop light, the stock light is already a 2 filament bulb and socket. There is another wire burried in the harness under the seat that connects to the second (brake light) filament. Run power from the bat to the brake switch to the brake light wire, and you're done.

Horn is easy, too. Power to the switch, switch to the horn, and horn to ground.

Good luck, and post up some pics when you're done!


Sorry for the lack of info. Sometimes you forget the most obvious
of info that should have been included.

2009 WR450F......

Not exactly sure on the rear turn signals as of yet. Something small
though. I just dont want anything sticking out that could get
broken off when I have one of my usual get offs.:lol:

  • Zadok

Posted February 12, 2009 - 06:46 AM

#7

Some more info on the Switches that are available....

12v 10amp On/Off Pushbutton, Black Boot. - Add $3.50

12v 10amp On/Off Pushbutton, Red Boot. - Add $3.50

2-12v 10amp On/Off, Red and Black Boot. - Add $7.00

12v 2amp Momentary, Black Boot. - Add $3.50

12v 2amp Momentary, Red Boot. - Add $3.50

2-12v 2amp Momentary, Red and Black Boot - Add $7.00

Also, the stock WR450F tail light assembly may already be
setup for brake light use. I will look into this today.

  • spidennis

Posted February 12, 2009 - 07:47 AM

#8

Also, the stock WR450F tail light assembly may already be
setup for brake light use. I will look into this today.


my 03wr250f was easy to wire to the rear brake light, the bulb fixture was already set up for it. just had to tap into the wire that wasn't used.

  • spidennis

Posted February 12, 2009 - 07:53 AM

#9

P.S if you want to see the end result on a WR I have pictures I can e-mail you.


time to get with the program motomanny and share those pics with all of us here!

  • spidennis

Posted February 12, 2009 - 07:55 AM

#10

Some more info on the Switches that are available....

12v 10amp On/Off Pushbutton, Black Boot. - Add $3.50

12v 10amp On/Off Pushbutton, Red Boot. - Add $3.50

2-12v 10amp On/Off, Red and Black Boot. - Add $7.00

12v 2amp Momentary, Black Boot. - Add $3.50

12v 2amp Momentary, Red Boot. - Add $3.50

2-12v 2amp Momentary, Red and Black Boot - Add $7.00


where did you get these switches? they're nice!

Visit the ThumperTalk Store for the lowest prices on motorcycle / ATV parts and accessories - Guaranteed
  • Zadok

Posted February 12, 2009 - 08:04 AM

#11

where did you get these switches? they're nice!


http://www.highwaydi...ef=BrakePerSw_2

Havent gotten them yet. Just want to make sure I can get
everything to work.

I think maybe Im not clarifying how simple I want this setup. I
basically just want to ADD turn signals to the bike by use of
the above switches. I dont want to make any changes to the
stock wiring for power on, lights, etc etc.

Im thinking maybe I can just go from the battery, inline fuse, relay, switch above, turn signal, ground ????

Will this work?

Dont even care about a horn. Never use one anyway. Dont care about
High/Low beams either. Basically I will use the stock tail light as
brake light. Then add turn signals and a mirror. Should be pretty simple
setup I would think. But wiring is my weakness, so I just want to make
sure this will work.

  • Zadok

Posted February 12, 2009 - 08:05 AM

#12

my 03wr250f was easy to wire to the rear brake light, the bulb fixture was already set up for it. just had to tap into the wire that wasn't used.


What type of setup did you use to activate the brake light?

  • spidennis

Posted February 12, 2009 - 08:16 AM

#13

What type of setup did you use to activate the brake light?


I used what you showed, that banjo pressure switch. I don't remember exactly what i did. I thought I had pics of what i had done, oh well. so I most likely tapped off the tail light with a wire down to the switch, then ran another wire up and into the unused wire right at the connector which is under the seat.

since my pressure switch is currently not working I'll be getting into it and I'll take more pics of what i've done.

  • 123BigcoopDawg576

Posted February 12, 2009 - 08:39 AM

#14

Basically I will use the stock tail light as
brake light. Then add turn signals and a mirror. Should be pretty simple
setup I would think. But wiring is my weakness, so I just want to make
sure this will work.


Basic 12v wiring is all you need to setup your 09 for dualsporting...with that being said, its hard to take a picture and explain what was done.

take your time and use your 12v meter and you will be fine.
:lol:

  • chipwich

Posted February 12, 2009 - 12:15 PM

#15

Zadok, you might have seen this, but just in case you haven't, it might help...

http://www.4strokes....port_wiring.asp

  • motomanny

Posted February 12, 2009 - 12:56 PM

#16

You're right but im having trouble figuring out how to post them in a forum.....i do have some pics in my garage though....sorry new to all of this kind of computer application.

  • spidennis

Posted February 12, 2009 - 01:05 PM

#17

You're right but im having trouble figuring out how to post them in a forum.....i do have some pics in my garage though....sorry new to all of this kind of computer application.


here's that link you'll want: "how to post pics"
http://www.thumperta...ad.php?t=454005

  • motomanny

Posted February 12, 2009 - 01:10 PM

#18

Thanks for the info on photo sharing....I will use that...unfortunately right now im at work (fire dept.) and am not allowed to down load programs to this computer. I will post some pics once im on my PC. Once you see this kit and how clean it looks you will agree its a very good option, as long as the hefty price doesnt scare you away.

  • 123BigcoopDawg576

Posted February 12, 2009 - 02:14 PM

#19

Once you see this kit and how clean it looks you will agree its a very good option, as long as the hefty price doesnt scare you away.


if you can do basic 12v wiring...then buying a "kit" imho is a waste of money especially on the wr that already has 90% of the wiring you need...i made that mistake on my 06 :worthy:

when i bought my 08, i bought the parts i waned and wired them in...total price for everything you need should be around 140 bucks (give or take what you buy) :lol:

  • motomanny

Posted February 12, 2009 - 04:23 PM

#20

To each his own I guess. I liked that I did not have to cut one single wire everything was pre manufactured with factory yamaha plugs nice low profile LED lights and now I have a plated wr in cali. that looks awesome and the lights won't break off in a spill, all installed in less that 1 hour. I do appreciate that you did it economically on your own that is definately commendable and gratifying. In the end we both have awesome bikes that are a blast to ride and versatil too and thats what matters.




 
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