2003 KTM 450 EXC relay wiring questions. Arrggggg

[rrrdbw]

My 203 KTM 450 EXC is street legal. Has front headlight, rear tail light and brake light. (rear brake only) . NO TURN SIGNALS! No Key, electric start and kick start. Never had relay switch so I have to start from scratch. I have watched all the youtube video and researched. Most of the video or articles are for existing turn signals adding LED lights with relay already in the picture.


1. I successfully added turn signals. Purchased a handlebar switch, got the headlight/tail light, turn signals and brake light to work. Wiring correct.

2. Issue is I do not know how/where to add/wire the flash relay. It is driving me F*cking insane for days now. My turn signals work fine without relay they are just not flashing. I am forced to click off and on

3. I purchased the correct relay and I am able to successfully flash when I connect. But I know its wired wrong.
a) the turn signals stay on , when i click turn signal left/right they would flash . Issue: light are always on even when engine is off.

b) I connect another way, they seem to work right, but when I cancel left/right signal the clicking noise continues.

I know it's in the wiring I can't figure it out. From the handlebar switch, I am working with 3 wires. Blue/Right signal Orange/Left signal and Gray?? I assume this is power and I have it connected to power/Ignition. Everything is working wired like this. I can't figure out where to add the relay switch.

*Relay switch is for motorcycle, 2 pin. L=load X=direct to battery
*adding 4 LED turn signals. (I can get them to flash so I know it's not relay load issue)

Please help. I need to know in detail what wires to connect. Assume I know nothing about wiring, so be specific.

Again I have all headlight, turn signals, tail light and brake light functional. Just need flash relay added to make it flash.

Thanks, in advance.

 

[augustiron]

maybe?

 

[boney]

Maybe? Possibly!

The relays on my old bikes were usually a two terminal can that was wired between the power source and the switch, just like the image above.

 

[rrrdbw]

Here's the dilemma. The wires off the handle bar switch are as follows. Orange=left turn signal
Light Blue= right turn signal
Gray= I am assuming it is ground. Look at picture, it is separate from the left and right connector.


From diagram and with many diagrams I have looked at. It does not say where/what the L=Load coming off relay goes to. I know the X goes directly to power source=battery


I am chasing my tail. Can an electrician chime in.

The handlebar switch is working correctly. As I mentioned the lights are working as they should , they are just not blinking because the relax is not connected.

 

[boney]

If you have a volt meter, set it measure DC voltage. Turn on the ignition, touch the red lead to the end of the grey wire and the black lead to some bare metal on the bike or the negative side of the battery. If you get a number greater than about 10 then the Grey wire is positive. Connect the Grey wire to the L on your flasher relay and the X to power.

If you don't read on:

So, the lights themselves won't work if they're not connected to a ground and a hot (or positive) wire... Where do the "other" wires connected to the lights go? Not the colored ones that go to the switch, but the ones that don't. If the "other" wires are the same color, chances are they're ground. If they go to the frame or ground or tie in to the negative side of the battery then the GREY wire is hot. Connect the GREY wire to L on your flasher relay. You'll either have to cut it and put connectors on the wire ends or find where you can disconnect the grey wire from it's power source and put it there.

If the other wires on the turn signal lights themselves, the ones that don't go to the switch, go to the battery or some other source of power then you should be able to connect them together at the flasher on the L terminal, and connect the flasher (X) to the (fused and switched) power source.

Still don't know and wanna play with fire? Try this: get a piece of wire, strip both ends of it about 1/4 inch. With the ignition off, clip one end to the positive side of the battery. DO NOT LET THE OTHER END TOUCH ANYTHING METAL ON THE BIKE. It will short the battery and could cause problems; things like fire and damaged electrical components. So, looking at the back of your switch, with the ignition off, carefully touch the bare end of the wire that you connected to your battery to the Orange and Light Blue wires where they're connected to the switch. If the lights light up when you touch the ends of the Light Blue or Orange wires then the GREY wire is positive.

Give those a try and report back.

EDIT

To clarify, L=load. you want to power the lights off that. If you find that the GREY wire is hot, then you want to disconnect they grey wire from it's power source and connect it to L on your flahser (and X to the power source.)

 

[rrrdbw]

This is how i currently have it wired,
The left/right front and rear signal lights connected to ORANGE/BLUE off the handlebar switch positive

Other wire off the left/right, rear/front signal lights connected to frame for ground.

Currently nothing off the turn signals are connected directly to Relay switch.

The GRAY wire off the handlebar switch I joined with the front headlight, that's connected to YELLOW wire coming off ignition. This gets power when the motor is running.



***Just tried your suggestion.
1. Direct connect wire to + battery
2. Touch ORANGE = lights come on
3. Touch Blue= lights come on

This happens when the GRAY wire is connected or not.


*** When i try to add switch to diagram.
1. On Relay X/B connected directly to + Battery
2. On Relay L connected to GRAY that's currently connected to FRONT headlight.
3. With ignition off =lights do not come on..BUT LOUD irritating beep from RELAY..thats with handlebar turn signla switch in off position or left/right still makes beeping sound no lights.
4. With Ignition on and headlights on. Same scenario--Loud beep...
a) signal lights turn on when i switch left/right on handlebar switch but not flashing.

 

[boney]

:dunno

Sounds like you've got it hooked up right when you insert it between the headlight and the switch on the Grey wire. I don't know why it's not working.

 

[D'Ecosse]

Follow the diagram by augustiron (except input to the relay should come from switched power, not directly from battery)
The pole of the switch (the grey) connects to the output of the turn signal relay - not to positive power and not to ground.
Ignition-fed power goes to the input side of the relay;
The two switch outputs then go to the left and right side signals; and the negative return of the signals goes to ground.