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| | #1 (permalink) |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Pitster Lighting Kit installation?? We got some of the X4 Motard bikes in stock today. A lot more prep work required on these than the normal dirt models for starters. Some new parts on these bikes so instructions may/should be used for guys ordering these things, but were nowhere to be found. I will say the new manual for the dirt models seems pretty good! I ended up having to round out the holes in the rear fender to get everything to mount properly in the rear. I did not bother with the mudflap that was included for now as its a really tight fit with the fender and the 2 piece tail light/plate bracket. I also had a Pitster lighting kit sitting in stock and I know these bikes are going to be for road use so I began the task of installing the lighting kit with wiring harness since it comes with a set of 4 blinkers + clutch perch mounted controls which we will need for street use. I figured I would just swap harnesses and equipment and that would be that. Before I go any further, installing even the stock front and rear light were not too straight forward, there was a brown missing on my tail light on the harness to plug into if its needed and on the head light I am not even sure if the colors were the same, but it was confusing as they were all just loose ends up there. Basically that is what prompted me to assume if this wasn't even easy, no way was I going to be wiring in blinkers to this stock harness! Well I did not get too far as basically only 1-2 things on the wiring harness are plug and play compared to about the 7-8 things in the box that are supposed to be run on this harness. The blinkers and rear tail light.. basically a guess of where they plug in, nothing matches up color code wise. The front light, dosent plug in etc etc.. Pitster if you have an actual schematic on this post this up, if anyone has installed this let me know whatsup. Was expecting this to be a plug and play unit as it sells as a kit...
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower |
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| | #2 (permalink) |
| Super Moderator Join Date: Feb 2005 Location: Windham, ME
Posts: 7,798
| Re: Pitster Lighting Kit installation?? Ah, you hit the same wall I hit. Near as I can tell, there is a ground line front and back, that's easy enough. The black feeds I'm guessing are power. So, in back, this means trial and error to see which wire feeds the running light vs high/signal. In front, we have to determine which color is high or low beam, which ever you want, and plug it in. I don't see any point plugging in the parking light, or trying to run the high and low beams at the same time. Where did you decide the rear mudflap goes? It almost looks like it goes on the swingarm, under the shock mount block? The mount holes are too close together to mount up under the seat, so thats my best guess. Test fitting everything back there it looks like I'm gong to swap in longer bolts for the rear fender mounts, I want a bit more thread in there. I also ended up shimming the tail light bracket, its narrower than the fender subframe. No biggie to sort. Does the lighting kit come with a complete wiring harness? Might be easier to use that harness rather than try to patch into the one that ships with the Motard. And yeah, the new manual is slick, the pics and diagrams are all of the right bike, it's decently written, it classes up the offering quite nicely.
__________________ http://www.x386.net/TTR 2004 ST3 - 'Duckie'?!?! 2005 CRF70RR - MiniGP Weapon 2005 CRF70 - Dirt Donk 2008 Pitster Pro X4 Motard 1991 GS500E - LRRS/CCS #771 |
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| | #3 (permalink) |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? I am using the wiring harness that Pitster supplies with the lighting kit, not the one that originally came on the Motard Edition bike, thats why I can't believe nothing they sell it with matches up and it is sold as a kit! Yea that mudflap.. no idea, I didn't even take the time to screw with it. On the one rear fender mount where it bolts the the subframe, I had to run the bolts without the washers that they originally came with as the washers butted up against the subframe and would not allow you to tighten them completely.
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower |
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| | #4 (permalink) |
| 3rd Gear Member Join Date: Sep 2004 Location: North platte, NE
Posts: 1,113
| Re: Pitster Lighting Kit installation?? the mud flap fits under the swingarm upside down, also we found out that the subframe is also different and the fender bolt holes need to be opened up, If you put our fender braces on the "new"x4/x4r you will need to drill them a little we had to drill the fender to fget it to fit. I am hoping this is just a batch of different subframes and I hope the next ones are back to the other fit . Last edited by mattmoto441; 02-15-2008 at 07:21 PM. |
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| | #5 (permalink) | |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? Quote:
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower | |
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| | #6 (permalink) |
| 3rd Gear Member Join Date: Sep 2004 Location: North platte, NE
Posts: 1,113
| Re: Pitster Lighting Kit installation?? it is the subframe, we tried to put the parts on an older 08 pitster and they fit, the older parts also would not fit the new bike. |
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| | #7 (permalink) | |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? Quote:
Keep this bumped up, I want to see if anyone figured out the lighting/blinker wiring..
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower | |
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| | #8 (permalink) |
| Super Moderator Join Date: Feb 2005 Location: Windham, ME
Posts: 7,798
| Re: Pitster Lighting Kit installation?? Ok, just finished assembling mine, plug both greens from the headlight into the green from the bike. Plug the blue from the headlight into either of the blacks from the bike, and that'll get you high beam. White is low, brown is park. In back, again, green to green, brown is the running light to plug it into the black from the bike. Green with a yellow stripe from the taillight will be used once you have brake light switches.
__________________ http://www.x386.net/TTR 2004 ST3 - 'Duckie'?!?! 2005 CRF70RR - MiniGP Weapon 2005 CRF70 - Dirt Donk 2008 Pitster Pro X4 Motard 1991 GS500E - LRRS/CCS #771 |
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| | #9 (permalink) | |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? Quote:
At this point I am glad I did not sell any of these non locally as it would have been a major headache.
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower | |
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| | #10 (permalink) |
| Super Moderator Join Date: Feb 2005 Location: Windham, ME
Posts: 7,798
| Re: Pitster Lighting Kit installation?? I ran into that too with the wide rim... definitely not enough room for a two piston caliper and larger rotor. I think the 1.85" wide rim that was initially announced as what would be up front would just slip by, but I'll take the 2.15" that came on it instead any day. The other tiny gotcha I came across, the throttle side grip needs to be cut flush with the throttle tube, but thats no biggie. I'm going to start trying to wire up a full lights and horn setup here shortly using an aftermarket switch cluster. I'll post a schematic once I've got it figured out.
__________________ http://www.x386.net/TTR 2004 ST3 - 'Duckie'?!?! 2005 CRF70RR - MiniGP Weapon 2005 CRF70 - Dirt Donk 2008 Pitster Pro X4 Motard 1991 GS500E - LRRS/CCS #771 Last edited by Kurlon; 02-16-2008 at 03:46 PM. |
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| | #11 (permalink) |
| PM Newbie Join Date: Jan 2008
Posts: 13
| Re: Pitster Lighting Kit installation?? I got 2 of these Motard bikes and yes I agree , no simple task throwing these things together.. You better have some experience putting bikes together right out of the box if ordering these babies... I too had caliper clearance issues with both bikes. No wiring diagrams for front or rear lights. No instructions at all (Which might be a good idea for your average joe). I got the rear to stay on constantly but no switch set up. Were these things supposed to come with the brake light switches. Please let me know by PM or post up on this issue. Mine just stays on. The on off brake light was a big selling factor for me. I gave up on the front headlight after a few tries. Thanks for posting your tip for the headlight wiring.. I'll try that tomorrow and see how it works out. I still don't know how I'm supposed to activate hi/lo beam. I'm with you guys on the RR fender needing to be drilled a bit to be bolted up. And yes the washers had to be left out running upward on the subframe because of clearance issues. As far as the rear mudflap , I gave up on that one too. I coudln't make heads or tails out of it. Because of my other issues I was a little ill & frustrated. I'm not going to go on about them yet. I'm going to get with gary to see about a fix before I say anything. Maybe i'm special and they only happened to me.. I had to grind down the whole diameter of 1 of the footpeg pins as well as shorten it a bit to get it too clear the shift shaft (it would not fit on either side). I thought the hand gaurds are cool for a mini I've had them on my 625smc and my 400sm only used them on the 400sm though and they kept my hands from getting ground down. The motor fired up and idled on the third kick which was a great suprise. I figured it would take a bit. I agree on the throttle tube needing to be moved in. I loosened mine a bit and moved it over to where the tube was flush with the handlebar to fit the hand guards easy.. I did not get to ride either due to rotten weather but I will post up after some break in rides. I wonder how many others have taken delivery of these bikes.. One more thing anybody know of a bolt on quick fit kickstand instead of toting around the prop stand. In case of legalizing it for the street. I hate to throw a good bike up against a wall but i've had to do it before.. We should post some good in action photos after we get too ride these things.. I have to wait for the weekends pretty much, for the school parking lots to open up.. No cool go cart tracks in my area.. Thanks guys for your input already.. |
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| | #12 (permalink) |
| Super Moderator Join Date: Feb 2005 Location: Windham, ME
Posts: 7,798
| Re: Pitster Lighting Kit installation?? As of right now my assumption on the lighting is it's not meant to be a street legal setup. It's just a constant light and tail light for night mobbing, similar to what many have rigged on their 50s. I still need to find some time to trace the stock harness and diagram it out, that unused 4 pin connector by the headlight has me intrigued. As far as the rear mudguard, it bolts to the underside of the swingarm. Take the rearmost two bolts out of the swingarm shock mount. Replace with the two long ones that come with the mudguard, and torque properly. Slide the mudguard on from the bottom, and use the two supplied flange nuts to hold it in place.
__________________ http://www.x386.net/TTR 2004 ST3 - 'Duckie'?!?! 2005 CRF70RR - MiniGP Weapon 2005 CRF70 - Dirt Donk 2008 Pitster Pro X4 Motard 1991 GS500E - LRRS/CCS #771 |
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| | #13 (permalink) |
| 5th Gear Member Join Date: Sep 2003 Location: KANSAS
Posts: 7,206
| Re: Pitster Lighting Kit installation?? Gotta love wiring. Actually, it's one of the most fulfilling parts of a bike build. The easiest way to do the clamshell and turnsignal/high/low wiring is to take apart the clamshell and look to see how the switches work. I've custom wired a few in my day, and look at the contacts in the switches to see what goes where rather then fooling around with a tester. On the turn signals, you'll have 1 wire that will be power, and a right and left wire on the switch. If the turn signals have two wires, 1 will be ground (green) and the other will be for the power. If you have single wire turn signals, the turn signal mount will be the ground and the single wire is power. Horn will have a power and ground, and the clamshell will tell what color wires go there. High/low same deal. Take apart the clamshell and diagram the switches... |
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| | #14 (permalink) | |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? Quote:
Z, the problem is, they did not come with this part The lighting kit, sold seperatly, did come with a switch for high/low, horn, blinkers (which we did figure out yesterday what each wire is) BUT there is nowhere to plug them on the existing harness, nor are they color coded to work with the wiring harness in the lighting kit even which is nuts. Oh yea, speedo reads in Kilometers per hour as well, not too helpful if you live in America. There appears to be 2 small rubber buttons on the tach as well, but don't do anything. I was told the bikes would have a kickstand, no kickstands. Oh yea the key, it doesn't turn the bike off, only the tach setup.. not sure what the point of that is.
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower | |
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| | #15 (permalink) |
| 5th Gear Member Join Date: Sep 2003 Location: KANSAS
Posts: 7,206
| Re: Pitster Lighting Kit installation?? That sure sounds like fun! I'm sure once Pitster returns from Indy, they will clarify and fix this. Does the motards also come with a brake lever with a built in switch for to trigger the tailamp and a pressure switch for the rear footbake so the rear taillamp works? From reading above, it doesn't sound to be the case. |
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| | #16 (permalink) | |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? Quote:
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower | |
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| | #17 (permalink) |
| Super Moderator Join Date: Feb 2005 Location: Windham, ME
Posts: 7,798
| Re: Pitster Lighting Kit installation?? On the instrument cluster, the right button toggles modes, trip, odometer, and time. The left button is the 'action' button, reset the trip, set the time, etc. (Haven't tried it yet though.) Underneath, in the upper right corner (throttle side) there is a third button that toggles between SAE an Metric. Noticed the neutral light doesn't seem to be wired on mine.
__________________ http://www.x386.net/TTR 2004 ST3 - 'Duckie'?!?! 2005 CRF70RR - MiniGP Weapon 2005 CRF70 - Dirt Donk 2008 Pitster Pro X4 Motard 1991 GS500E - LRRS/CCS #771 |
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| | #18 (permalink) |
| 3rd Gear Member Join Date: Oct 2003 Location: Cape Cod Ma. 02660
Posts: 7,486
| Re: Pitster Lighting Kit installation?? Are you guys using a Test light..? |
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| | #19 (permalink) | |
| Advertiser Join Date: Aug 2004 Location: East Coast - PA
Posts: 3,874
| Re: Pitster Lighting Kit installation?? Quote:
__________________ Website - www.ahpminis.com Email - mark@ahpminis.com AHP - TB -Sano - RB - Kitaco - iShock - Fox - Marzocchi - F50s - Utopia - Takegawa - Crower | |
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| | #20 (permalink) |
| Super Moderator Join Date: Feb 2005 Location: Windham, ME
Posts: 7,798
| Re: Pitster Lighting Kit installation?? Yeah, I had to really press down initially, but all three worked. I was able to change to MPH, reset the trip meter, etc. Only thing I haven't tried is setting the clock. Be sure to hold them down until you see something happen, looks like they've got a long de-bounce timer.
__________________ http://www.x386.net/TTR 2004 ST3 - 'Duckie'?!?! 2005 CRF70RR - MiniGP Weapon 2005 CRF70 - Dirt Donk 2008 Pitster Pro X4 Motard 1991 GS500E - LRRS/CCS #771 |
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