Brake light system overhaul with LEDs

Introduction

In this article, we will be adding extra brake lights, LED brake lights, LED license plate lights, and a Back Off brake modulator.

If you would like to add to your visibility, but do not want to stop with just changing bulbs or adding bulbs to the side pods, here is how to change it all.

Tools

• Wire Strippers/Cutter
• Hitachi Connector Crimper (optional; should be able to use standard crimper)
• Ruler (optional)
• Pen/marker (optional)
• Soldering Iron
• Knife/scissors: to cut shrink wrap tubing (optional)
• Heat Gun/Lighter/Blow Dryer/Heat Source: to shrink the shrink wrap tubing (optional)
• Phillips screwdriver
• Hands-free assistant (optional but helpful)

Supplies

• Solder
• Shrink wrap tubing (optional)
• Wire Connectors, preferably Hitachi 3 wire. A recommended Hitachi supplier is Eastern Beaver. They sell Sumitomo connectors, as Hitachi never really made Hitachi connectors. Shipping & service from Japan has been stated as quite good.
• Electrical tape (preferably black, red and blue)
• Copper wire (preferably black, red and blue)
• License plate frame
• #1157 LED bulbs for the pods. There are good and bad LED suppliers. Custom Dynamics is a trusted company. Note that 1157 incandescent bulbs are not recommended for the pods.
• Brake light modulator (e.g., Back Off by Signal Dynamics)
• 3-wire socket (part # 84725 at AutoZone)
• O-rings to help seal and secure the sockets (a couple different sizes, the smaller one being 1/16’’ width with 1’’ outside diameter).

Why Hitachi connectors were used

You can use the more common (in the US, that is) Molex .062 connectors, but most Japanese bikes use Hitachi connectors. If you use Hitachi connectors you can create most of the wiring harness on the bench. Then you simply unplug the central brake light and plug in your harness, and you are mostly done. And that makes your life much easier.

To use: You plug them together. The advantage of the Hitachi connectors is that they are the ones already on the bike, and you can use the existing connectors to tie into without having to cut the existing wires. Go here for more information on working with Hitachi/Sumitomo connectors.

Be sure to test the wires to determine the ground, running and brake lines prior to securing the prongs in the connectors. Not everyone uses the blue, black and red combination that is on this bike. Feel free to change the colors. This project stayed with the factory layout and added a band of colored electrical tape to any extra wiring that was in a different color.

Extra lights

First, add the connectors to the ends of the sockets. Then follow these directions.

Note that this can be done without removing the assembly (with the lights still on the bike). Also, you don't have to use the plate that comes with the sockets. Place an o-ring on the back side of where the socket inserts and secure it with super glue. Then add a smaller (1/16’’ width, 1’’ outside diameter) o-ring in the small recessed portion of the reflector and secure this with super glue. Because the LED lights used fit very snugly in the sockets, you might want to place them in the sockets prior to securing the sockets in the reflector housing. Then insert the sockets (with bulbs in place) and secure them with super glue/epoxy. Hold them in place for about ten minutes before releasing them to stay on their own.

License Plate Frame

Secure your plate to the frame using appropriate hardware. Next, run the wires (one per LED strip) under the seat. Since there are two wire sets, simply twist these together and use one connector for both wire sets. Hook them into the brake light wiring (obviously).

Wiring Tangle

Then, take pieces of (roughly) 4" wire to use as the added lines to connect the various components.

Start by adding two lines to the Back Off module, so that you can use the connectors (notice the blue tape on the red and white/red wires).

Next, prepare the wires to split the single brake line into four brake lines (each side pod, central brake, and license plate frame). Twist these wires together, then solder. Then, place the plugs (pins) on each end.

After the soldering, put the heat shrink tubing in place and treat with a blow dryer or lighter. Finally, place the connectors on each end.

Snap the connectors together, and secure the Back Off module under the seat, using the included double-sided adhesive backing.

Running lights

Brake lights (on cycle)

Brake lights (off cycle)