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PostPosted: Sun Oct 05, 2008 7:01 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
My sons brain was not wired for operating motorcycles,atvs or Odysseys for that matter.
So after seeing smoke billow from under the clutch covers and my son with that "I dunno"
look, because emergency brake is on. I decided to come up with some indicator lights that
will show the rider when the Odyssey is in neutral and when the emergency brake is on,
pictures are better than words or something like that.
I wanted a clean/factory stock "look" that was not only water/sand proof but also reliable.
I started with two Borg Warner neutral saftey/-back-up switches (part numer S9255) that
were designed for an 82-91 Camaro. I used a neutral/oil/high beam indicator panel
from an 83 Yamaha XZ500 Vision. This panel fit nicely into the Odysseys steering wheel
with minimal modifications. This particular indicator panel had all the necessary light
colors for my project .The neutral light was used for my neutral position indicator light,
the oil light was used for my emergency brake position indicator light and
I tied the high beam light into the high beam switch in the Odyssey steering wheel.
Instead of explaining each and every step of the instalation process I will
let the pictures do the talkin. Ill briefly describe what each picture is showing.


Attachments:
File comment: two Borg Warner switches for neutral and emergency brake position activators,waterproof fuse
holder,Yamaha indicator panel and 1"X1/8" steel stock used for switch brackets

P1000348.JPG
P1000348.JPG [ 1.28 MiB | Viewed 728 times ]
File comment: switch mounted in steel stock and ready for "neutral position" bracket fabrication.
I used a castle type speed nut to hold the switch in place.

P1000350.JPG
P1000350.JPG [ 1.31 MiB | Viewed 728 times ]
1.jpg
1.jpg [ 45.78 KiB | Viewed 537 times ]
2.jpg
2.jpg [ 78.21 KiB | Viewed 537 times ]
File comment: bracket complete besides rustproof dip and drilling mounting holes
3.jpg
3.jpg [ 80.69 KiB | Viewed 537 times ]
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PostPosted: Sun Oct 05, 2008 7:12 pm 
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Joined: Sun Apr 27, 2008 5:36 am
Posts: 1345
Location: Benson, NC
Good idea, I just finished fooling with the parking brake today so its function is fresh in my brain. How will you trigger the switch to turn on the light one the brake is pulled? does ythe brake line just go through the device you have made?


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PostPosted: Sun Oct 05, 2008 7:14 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
installation continued...


Attachments:
File comment: transmission lever was slightly beveled to allow lever to pass over the swith without binding. Both sides of the lever were filed
P1000358.JPG
P1000358.JPG [ 1.3 MiB | Viewed 728 times ]
File comment: switch mocked up to properly align switch to transmission's shift lever,notice bracket is very close to gas tank, will later add rubber shield in case tank or bracket moves.
P1000366.JPG
P1000366.JPG [ 1.27 MiB | Viewed 729 times ]
File comment: attaching wire, wire loom and heatshrink to switch
4.jpg
4.jpg [ 83.56 KiB | Viewed 537 times ]
5.jpg
5.jpg [ 88.69 KiB | Viewed 537 times ]
File comment: attached neutral switch bracket to frame with muffler's "right" bracket bolt. Will later add another bolt to bracket for better rigidity
6.jpg
6.jpg [ 48.95 KiB | Viewed 537 times ]
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 Post subject:
PostPosted: Sun Oct 05, 2008 7:21 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
installation continued....


Attachments:
File comment: bracket complete, wired and installed. Notice extra bolt and also rubber shield installed near gas tank
P1000394.JPG
P1000394.JPG [ 1.41 MiB | Viewed 728 times ]
File comment: emergency brake switch bracket complete besides rustproof dip. Used a jam nut to hold switch in place, had to grind jam nut to a smaller thickness due to lack uf threads on switch.Used loctite on threads
P1000380.JPG
P1000380.JPG [ 1.51 MiB | Viewed 728 times ]
File comment: Dipped bracket in rustoleum's rubber coating to help control rust on bracket
7.jpg
7.jpg [ 67.73 KiB | Viewed 537 times ]
File comment: bracket complete, wired and installed. Notice extra bolt and also rubber shield installed near gas tank
8.jpg
8.jpg [ 59.63 KiB | Viewed 537 times ]
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 Post subject:
PostPosted: Sun Oct 05, 2008 7:29 pm 
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Joined: Sun Apr 27, 2008 5:36 am
Posts: 1345
Location: Benson, NC
gotcha, I spoke too soon...


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PostPosted: Sun Oct 05, 2008 7:37 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
installation continued....


Attachments:
File comment: emergency brake switch bracket completed, wired, dipped and installed. Bracket was installed on the e-brake lever's rear mounting bolt. I used a longer bolt, installed a washer between e-brake mount and bracket,installed a star washer between bracket and
P1000400.JPG
P1000400.JPG [ 1.35 MiB | Viewed 728 times ]
File comment: slightly modified the Yamaha's indicator panel by cutting off the ignition portion and beveling the sides.
P1000379.JPG
P1000379.JPG [ 1.36 MiB | Viewed 728 times ]
File comment: this pic shows ebrake in the "off "position
9.jpg
9.jpg [ 72.36 KiB | Viewed 537 times ]
File comment: this pic shows the e-brake pulled up and engaged. Notice the switch is now engaged.
10.jpg
10.jpg [ 86.07 KiB | Viewed 537 times ]
File comment: mocking up Yamaha's indicator light assembly in the Odysseys steering wheel compartment.
11.jpg
11.jpg [ 73.45 KiB | Viewed 537 times ]
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 Post subject:
PostPosted: Sun Oct 05, 2008 7:55 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
continued....


Attachments:
File comment: indicator panel mounted,I used a simple 4 pin plug for easy removal.When installing make sure plug and wires are not obstructing the throttles lever travel and cable.Ground,and both switch wires were pulled through the Odysseys steering wheel grommet
P1000404.JPG
P1000404.JPG [ 1.25 MiB | Viewed 728 times ]
File comment: Both switches have two terminals.One wire from the terminal of each switch goes to the steering wheel and the other goes to here,the Odysseys regulator. From the rectifier is a black wire, this wire feeds the lighting,starter relay etc.
P1000406.JPG
P1000406.JPG [ 1.25 MiB | Viewed 728 times ]
file3.jpg
file3.jpg [ 72.33 KiB | Viewed 560 times ]
File comment: Yamaha instrument panel ready for installation..Wait my Odysseys now a HO. Removed H and O then later sanded HO residue with 250 grit up to 1500 for nice surface
12.jpg
12.jpg [ 67.78 KiB | Viewed 537 times ]
13.jpg
13.jpg [ 72.33 KiB | Viewed 537 times ]
File comment: New fuse block
14.jpg
14.jpg [ 85.98 KiB | Viewed 537 times ]
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 Post subject:
PostPosted: Sun Oct 05, 2008 8:00 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
The fused holder was not necessary however if my indicator panel, switches or wiring shorts it will be easier to trace with this fuse in place, I used a 5 amp fuse. All three indicator lights were grounded at the rectifier bracket's grounding bolt. You can see two green wires there. I grounded them there so it is easy to find later if I have a bad ground.
I thought about simply getting some panel mounted LED indicator lights for this project but no one seemed to know if the lights would show up in direct sunlight. I could have gone with super bright leds but then they would be blinding at night. I figured a factory panel would be built and suited for both daytime and night time applications. This panel shows up well in direct sunlight and the high beam indicator is not glaring at night.


Attachments:
file1.jpg
file1.jpg [ 54.57 KiB | Viewed 560 times ]
file2.jpg
file2.jpg [ 43.73 KiB | Viewed 560 times ]
File comment: new loom to stering wheel
15.jpg
15.jpg [ 85.25 KiB | Viewed 537 times ]
16.jpg
16.jpg [ 54.57 KiB | Viewed 537 times ]
17.jpg
17.jpg [ 43.73 KiB | Viewed 537 times ]
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 Post subject:
PostPosted: Sun Oct 05, 2008 9:21 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
Hey Hoser I was thinking this should go in the projects thread. If so, you can move it there...Marc


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PostPosted: Mon Oct 06, 2008 12:14 am 
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Joined: Sun Jul 16, 2006 8:46 am
Posts: 5244
Location: Seguin, TX (near San Antonio)
Please don't mix the rock star and Red Labeled Beer... We would have a wide awake drunk... :shock:


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PostPosted: Mon Oct 06, 2008 12:57 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2702
Location: Upland, Ca
Great idea.


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PostPosted: Mon Oct 06, 2008 1:30 am 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
shoubadaba wrote:
Great idea.


Thanks. Now I need to come up with a low fuel light, Hmm might have to mix some red labeled beer and Rock Star and do some wide awake brainstormin :-)


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PostPosted: Mon Oct 06, 2008 1:59 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2702
Location: Upland, Ca
Just remember don't use a lighter as a source of light to look into the tank.


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PostPosted: Tue Oct 07, 2008 8:31 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5508
Location: New Jersey
I like the 3rd light application-you have any issues with running the extra light?


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PostPosted: Tue Oct 07, 2008 8:53 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
shoubadaba wrote:
Just remember don't use a lighter as a source of light to look into the tank.

I had a friend that did that, I havnt seen him since :shock:


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PostPosted: Tue Oct 07, 2008 9:06 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
Mudbogger wrote:
I like the 3rd light application-you have any issues with running the extra light?

The cyclops(extra) light is wired in paralell to the left and right light. No issues as far as pulling too much current. My other Odyssey has three headlights as well plus a bosch water pump(? amps), fan(2.5 amps). I havnt experienced any problems with the charging system or electrical system problems.The three headlights don't seem to give me any more lighting in the distance but what it does do is give me better peripheral. I aim the left light slightly left and the right light to the right, center aims dead center.


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PostPosted: Tue Oct 07, 2008 9:29 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 796
Location: Bolton Ma
Very Cool!

Good job


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PostPosted: Tue Oct 07, 2008 10:04 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
Muchas Gracias


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PostPosted: Thu Oct 09, 2008 10:20 pm 
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Joined: Sun Jul 16, 2006 8:46 am
Posts: 5244
Location: Seguin, TX (near San Antonio)
stix9567 wrote:
Munches Grassyass


you need to work on your hooked on phonics tape...


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PostPosted: Thu Oct 09, 2008 11:15 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
Turbotexas wrote:
stix9567 wrote:
Munches Grassyass


you need to work on your hooked on phonics tape...


Or as the hippies say "much grass" !


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PostPosted: Mon Oct 13, 2008 9:31 pm 
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Joined: Fri Jan 12, 2007 2:17 pm
Posts: 2825
Location: Wichita ks
Very nice. You could hook up the third light to the high beam via relay so you could run low beam for runout to dunes and other to save current draw at idol and then hit high beam turining on all three for high speed running. I like the indacator set up I know turbo will want one for the bling machine. Very inavating.


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PostPosted: Mon Oct 13, 2008 10:04 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
Good idea about high beam. Or I could wire single light for heading out to dune then hit high beam and SHAZAM it lights the other two, if one is legal, During Sandfest they were checking all lighting, and going through bags for the gangha, that's marijuanna for non Jamacans. I hope this thread gives someone the idea and maybe they can improve on it. Its just something I thought up in a weekend with nuttin to do.


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PostPosted: Fri Apr 04, 2014 8:09 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
I mounted the 3rd headlight on both my 350's, been keeping an eye out in the want ads to see if they ever come back up for sale providing no one removed the cyclops light.


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PostPosted: Sat Apr 05, 2014 8:06 am 
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Joined: Sun Apr 29, 2012 12:45 pm
Posts: 286
Location: South-Central Pennsylvania
Sorry I missed this back when you posted it. Very well done... how did the switches and brackets hold up in use?


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PostPosted: Sat Apr 05, 2014 5:20 pm 
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Joined: Mon Oct 08, 2007 12:39 am
Posts: 3157
Location: Oklahoma City, OK
John l wrote:
Sorry I missed this back when you posted it. Very well done... how did the switches and brackets hold up in use?


Thanks, the switches were for external use on a vehicle, I think they were for reverse light and mounted on the transmission. I never had any issues with brackets coming loose or switches failing. I ran the machine several hard dune rides for about two years


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