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Old 07-03-2006, 02:41 PM   #1
alpiv OP
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Joined: Dec 2004
Location: Indianapolis, IN
Oddometer: 2,173
XR650R Dual Sport KIT (Home Built)

Ok, I have a 2000 XR650R and I had a Trick Dual Sport Kit (sold with my KTM).
Now I have to installed the following:


2) 12 VOLT REGULATOR / RECTIFIER

3) 12 VOLT SEALED BATTERY


Now that I have sold off the Trick-Dual sport kit.. I need to replace the headlight with the following:
1) UFO head light with high/low bean, parking light and
with flush mount turn signals.

2) Horn

3)
Universal 12V turn signal flasher
Works on AC or DC



4)
COMBINATION SWITCH



Now that I have all this I can build my kit...
The wiring for the switch lays out like this:

Now I need some advice from those who have background in this...

I come off the stock stator into the
12 VOLT REGULATOR / RECTIFIER...
Then into the battery..
From the battery I run the ground and hot wire up front.. and also run my rear turn cycle wires to the front of the bike...

Now the UFO head light has the following:

1) Main head light -- Three tabs two which run to the back of the bulb and one tab which is located to the right of the bulb..

not sure the sequence of the bulb.. is it?
HIGH LOW Ground

or
LOW HIGH Ground

Also....

with the should I run the power and ground coming from the battery into the switch and then run the rest of it to the headlight as is defined in the diagram above...
Diagram did not show up.. crap

Many thanks

alpiv screwed with this post 07-03-2006 at 06:34 PM
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Old 07-09-2006, 11:18 AM   #2
UngaWunga
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Joined: Jan 2005
Location: NH
Oddometer: 6,849
Quote:
Originally Posted by alpiv
Now the UFO head light has the following:
1) Main head light -- Three tabs two which run to the back of the bulb and one tab which is located to the right of the bulb..

not sure the sequence of the bulb.. is it?
HIGH LOW Ground
or
LOW HIGH Ground
WIth that switch, there's a seperate wire to the high and low beams. Then run each headlight to ground. Power runs into the switch before going ot the headlights.

Quote:
Also....
with the should I run the power and ground coming from the battery into the switch and then run the rest of it to the headlight as is defined in the diagram above...
Diagram did not show up.. crap
Take a look at the pinout for the switch. Different components have different inputs via the switch.
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Old 07-09-2006, 04:13 PM   #3
alpiv OP
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Joined: Dec 2004
Location: Indianapolis, IN
Oddometer: 2,173
Many thanks.. Got the High/low switch working, just have to figure out turn signal layout...
Tried to do it this way...
Power to turn signal/switch .. From switch to turn signal.. then out turn signal to signal flasher..
Yet no go with this setup..

Ideas???
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Old 07-09-2006, 08:52 PM   #4
UngaWunga
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Joined: Jan 2005
Location: NH
Oddometer: 6,849
Quote:
Originally Posted by alpiv
Many thanks.. Got the High/low switch working, just have to figure out turn signal layout...
Tried to do it this way...
Power to turn signal/switch .. From switch to turn signal.. then out turn signal to signal flasher..
Yet no go with this setup..

Ideas???
power to flasher, then to switch, then to each side of turn signals, then to ground.
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Old 10-03-2006, 01:29 PM   #5
Mercury264
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Joined: Nov 2005
Location: Masshole
Oddometer: 21,778
I am trying to add the switch you listed in your first post to my 2K DRZ 400E. The bike already has a front and rear light so at this point I am trying to wire up the lfront ight, horn and kill switch. I will then move onto the blinkers.

I have figured out the headlight - I dont have a high and low just a single light that I wired up to the Hi switch (the schematic is incorrect actually in that the Hi and Low beam are the wrong way round - i.e. yellow and green are the wrong way round) so I can at least turn it off and I get the LED to show me it's on.

The biggest issue I have is the horn and kill switch. The basic problem is the Horn and Kill switch ground are the same wire out of the switch unit. If I wire the kill switch wires up one way the bike won't start (because the kill switch wire that gets grounded to stop the engine is being grounded through the horn) and if I do it the other it blows the main fuse when I use the horn switch (because I am probably directly grounding the positive to earth and thus blowing the fuse).

I have searched and searched all over without finding the solution to this.

So the big question is.....did you fit your kit and if so how did you wire up the Horn and Kill Switch ?

Course...once I figure this out I then have the joy of fitting the indicators

If you fitted them...any help in that area would be most welcome.

Cheers...
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