Enclosed are the step by step instructions I used to make custom LED auxiliary/running lights. The intent of the lights are to supplement the KLR650 headlight. The advantages of this lighting system are:
1. Bight lights = increased visibility. A safety issue
2. 2x additional forward facing bright lights gives other drivers a depth perseption in judging your distance relative to their location.
3. LED’s are very vibration resistant, never burn out, and are low power consumption. The ones I selected are the brightest I could find within a 1 inch diameter cluster. This system consumes 5.4 watts total!
Note: No LED auxiliary lights are commercially available, so I was forced to make my own. There are 4x phases of this install.
1. LED bulb evaluation.
2. Light attach bracket to KLR650 (fellow KLRworld Mark was the inspiration for my design).
3. LED bulb attach to light housing.
4. Wiring to bike.
The Bracket material was 6061-T6 at .10 inches thick. It can be found here for $11.87, all you need is a 12 inch x 12 inch size:
The LED’s can be found on E-bay here for $13.50 each:
The auxillary lights can also be found on E-bay here for $14.99
The cost of the modification costs about $54 total!
start all projects by reviewing topic
light bracket overall size 12 inch x 7 inch
remove front fender
measure attach bracket pad “land” size
gross trim iteration 1.
after the band saw
locate attach holes, this bracket will be part of the fender stack-up
check hole size
drill and deburr
time to place back on bike
check clearance. Does not hit the nerf bars! That’s good.
light will be mounted about here
this is the light to mount. This one came with a 55 watt H3 type bulb. I replaced the as delivered bulbs with these 35 watt bulbs
need this 12 volt DC source for testing. It actually puts out 14 volts.
amp and volt meter
shrink wrap kit
wire connector kit
35 watt H3 bulb output
measured output = 3.016 amps or 42 watts
This is the LED I’ll be swapping out for that H3 incandescent bulb.
measured output =.192 amps or 2.7 watts per bulb
bulb diameter = 1.034 inch
will fit the bulb deep and securely in this light housing
side by side . Small LED flashlight, normal 2 D cell flashlight, 12 volt LED light, and 35 watt H3 bulb.
LED has cluster lights shining to the side
measure small diameter = .577 inches
power-up the LED’s. very bright and cool to the touch
light from rear
need to attach(glue) this plastic washer to the LED’s
washer size outer diameter = 1.258 inch. Can get at Home Depot
measure and trace
best to hand file to the marking
press fit on the LED’s
need to attach some of this reflector tape to those washers
trace and cut
attach to LED
disassemble these new lights
mark trim line
will fit LED deep in here
ready for cutting/trimming
since the metal is so thin, best to route to trim line. Drill will thrash the housing. Spotface won’t work either.
slowly open-up the hole
blow out particles collected
nice centered hole to accept the LED bulb
center LED bulb in hole
tape in place. Note: I destroyed a light housing in an earlier attempt at this project by gluing the bulb in place at this step. The fumes given off while the glue is curing got into the reflector area and stuck to the reflector and glass. This made the reflector “dull”. Tape works fine. Although not clearly shown it is fully taped up and sealed.
like in this view
the LED bulb extends far into the light housing and is secure
remove the baseplate for trimming
want it flush up to the bracket
measure and mark. Need to take a little off the edge
tad bit off the end
re-assemble. Note: I reversed the light bracket to the rear
will fit like this
final bracket trimming required
mark trim lines
band saw trim
disc sanding trim
light attach holes
drill, deburr, and countersink
quick check on fender
attach on bike
adjustable sturdy and robust design
check clearance. No issues
A-OK here too!
make wire connectors. White = 12v ground. Black and Red = 12v +
crimp and shrink wrap
Using this on all electrical connects to keep water out of the connections
light wiring all done
view of system with no power
wire connection in faring. No binding issues when turning handle bar
the bike side connection is covered here “KLR650 Marker lights install and review”:
I’m basically tapping into the city light leads in the front faring.
fire up the lights!
with headlight on
close up of LED light
off centerline view
1/4 view lights off
forward view lights on
1/4 view lights on. Note small marker light on faring
with camera filter
off front view
Review of Mod.
1. Very bright system. I’ll leave them on always.
2. Low power consumption 5.4 watts total.
3. Low cost modification $54 total
4. Light system will outlast the bike
In summary I’m very pleased with the project outcome, It exceeded my expectations.