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Old 05-29-2012, 02:15 PM   #1
Hondo OP
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Thumb 990 Adventure Turn Signal Repair

So you hit your turn signal in a crash or a maybe a tree branch whacked it, and you think you need to replace the whole assembly?

Think again.........

The turn signals are designed to break away the bulb housing from the stalk in just such an occurence.

Here is what my front left signal looked like after I laid the bike down -



During the crash the lens disintegrated and the bulb housing separated from the stalk. All we need for the repair is a new lens ($5.00 US) vs a complete turn signal ($20.00 US).

First, remove the screw at the back of the signal- this screws into the lens (or what's left of it) -



Then remove the bulb reflector from the housing and seat the housing onto the stalk -



Then slide the reflector completely onto the stalk (in the groves) -





this will set the reflector completely into the housing -



Here is the lens from KTM -





Insert the guide tab of the new lens into the housing slot and seat the lens fully-



Tighten the screw in the back-



Your repaired signal is as good as new -



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Old 05-29-2012, 02:28 PM   #2
Dagwood_55
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I recently broke the lenses on my bike and I thought I had to buy the whole assembly @ around 17 bucks. Did'nt know you could just buy the lense.
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Old 05-29-2012, 02:59 PM   #3
Hondo OP
What if its a Samsquamch?
 
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Quote:
Originally Posted by Dagwood_55 View Post
I recently broke the lenses on my bike and I thought I had to buy the whole assembly @ around 17 bucks. Did'nt know you could just buy the lense.
Exactly why I wrote this up!
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Old 05-29-2012, 06:02 PM   #4
Narsisco Lopez
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Yep... figured that one out already

So Leigh... you didn't opt for the self-healing plastics/paint option?

My brother can probably wrap those tanks for ya
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Old 05-29-2012, 06:21 PM   #5
Apple Jam
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Quote:
Originally Posted by Hondo View Post
Exactly why I wrote this up!
Hah, I've figured that out....like.....at least 6-7 times already
The first time was within 5 days of riding it home...

But, thanks for the post for others, I was pretty happy when I found out it was only $5,
when all I could see were BIG KTM $$$$$ signs in my head, that first time...

I buy them 2 at a time. Bulk Rate
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Old 05-29-2012, 06:24 PM   #6
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Quote:
Originally Posted by Narsisco Lopez View Post
My brother can probably wrap those tanks for ya
Don't you dare, Hondo.... I just LOVE the looks of a properly scratched up KTM....
Nice !!!


Quote:
Originally Posted by Hondo View Post
.....after I laid the bike down - .....


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Old 05-29-2012, 06:45 PM   #7
Nut Clutch
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My buddy crashed his DR650 and broke a turn signal off. Over $65 for a single Suzuki turn signal. Thank god for these Austrian bikes with their inexpensive parts!
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Old 05-29-2012, 07:09 PM   #8
Hochtouren
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My first trip into the weeds resulted in a dangling light, but mine separated from the mounting stem - don't think the new bulbs separate like yours. I thought I could press the stem back into the body, but once it's out, it's out. I think the replacement was 17CDN, so a nice surprise. I was bracing myself for some 70 dollar stupidity, but +1 on reasonable Austrian parts. More orange kool-aid please.
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Old 05-29-2012, 07:26 PM   #9
Hondo OP
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Mine is a 2011.

You have to remove the screw on the back of the bulb assy to free up the reflector/light bulb socket.

Only then can you put the bulb assy back onto the stem. When you then install the reflector over the stem groove does it all become one piece.

The best way to see this for yourself is to take one apart- takes just a few minutes.
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Old 05-29-2012, 09:22 PM   #10
SierraJeep
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For what it's worth, KTM uses those same turn single lights on some of their other bikes (like the EXCs), so most of the shops carry the replacement parts (because they always break).

Good of you to post the "how to..." so folks can learn this when it becomes their time. It's just a matter of when.
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Old 05-30-2012, 12:05 AM   #11
Salzig
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Quote:
Originally Posted by SierraJeep View Post
For what it's worth, KTM uses those same turn single lights on some of their other bikes (like the EXCs), so most of the shops carry the replacement parts (because they always break).
So, how do you guys would rate a dealer that answers: "I don't stock that stuff. I have to order it and you must pay the shipping."?
Not to mention it was the first and then last time he saw me
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Old 05-30-2012, 06:46 AM   #12
Apple Jam
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Quote:
Originally Posted by Steve Lavigne View Post
My buddy crashed his DR650 and broke a turn signal off. Over $65 for a single Suzuki turn signal. Thank god for these Austrian bikes with their inexpensive parts!
My wife's DR200 "broke" a rear blinker, somehow....all by itself,.... maybe....
It was cheaper to buy FOUR new LED blinkers from ebay, than it was to buy the stock one from the dealer

Quote:
Originally Posted by Hochtouren View Post
I thought I could press the stem back into the body, but once it's out, it's out. ......More orange kool-aid please.
You gotta remove the front fairing (or the tanks, if Safaris), unplug the blinker wire,
then pull the nut off the back of the threaded rod with the hole for the wire in it. It has a hex shaped flange(?) on the blinker end.

It's hard to re-attach it to the blinker, but stretch and twist the blinker base while holding the threaded rod with pliers, and it goes back on to the metal threaded rod,.... then re-install

After about four times of this, the blinker base becomes more forgiving, and it goes on easier,
.....but it also gets knocked back off easier.
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On the other hand, if it has been logged or mined and roads already exist,,
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Old 05-30-2012, 06:27 PM   #13
Hochtouren
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Quote:
Originally Posted by Hondo View Post
Mine is a 2011.

You have to remove the screw on the back of the bulb assy to free up the reflector/light bulb socket.

Only then can you put the bulb assy back onto the stem. When you then install the reflector over the stem groove does it all become one piece.

The best way to see this for yourself is to take one apart- takes just a few minutes.
Yeah, did that but the rubber collar that goes in the groove on the nut was torn/distorted enough that it wouldn't seat again and retain the assembly on the stem. Pressed back together, looked a bit soggy, unbolted, replaced, waiting for next trip into the rhubarb... $17 replacement also gave me an excuse to go to Blackfoot Motorsports and ogle the GoPro's and Sidi rains I've been coveting.
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Old 05-30-2012, 06:29 PM   #14
Hondo OP
What if its a Samsquamch?
 
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Quote:
Originally Posted by Hochtouren View Post
Yeah, did that but the rubber collar that goes in the groove on the nut was torn/distorted enough that it wouldn't seat again and retain the assembly on the stem. Pressed back together, looked a bit soggy, unbolted, replaced, waiting for next trip into the rhubarb... $17 replacement also gave me an excuse to go to Blackfoot Motorsports and ogle the GoPro's and Sidi rains I've been coveting.
Understand- sometimes ya just gotta replace the whole thing -
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Old 08-02-2012, 02:25 PM   #15
Deathbone77
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Nice
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