Custom Dynamics Technical Bulletin Troubleshooting Connection Issues with Turn Signals This bulletin is for the purpose of helping customers solve connection/operation issues on Custom Dynamics LED replacement turn signal clusters with plug-in bases. This is applicable for multiple makes with 1156, 1157, BAZ-3 and 7507 bulb sockets. So you ve decided to upgrade your turn signals. You want added visibility for the road and to do it in style. Custom Dynamics LED turn signals give you just that. You ve received your clusters, installed them following the instructions and you just can t get them to operate correctly. We can t assume it is the product before examining the factors that can cause connectivity issues. What to do First Don t panic! There are many different variables at work here. Let s cover how to check if the cluster is working. For a cluster that wont light at all: 1. Try it in the socket on the opposite side and test function. If it still does not light, then try below. Single Ground wall [ - ] Dual 2. Test the cluster off the bike by using a 9 or 12 volt DC battery with wire leads. See Bulb base diagram right for examples of single and dual contacts. Touch the negative lead from the battery to the metal side of the cluster base. Next, touch the positive lead from the battery to the bottom contact. The cluster should light up. Now that we have confirmed that the cluster is working, we should then take a look at the environmental factors that can affect operation. Turn Power [ + ] Run/Turn Power [ + ] LED base diagrams: Left is a single contact 1156 base, the right is a dual contact 1157. Both are typical on all Harley-Davidson models. Environmental Factors There are many factors that can affect the normal operation of our LED replacement turn signal clusters. It could be a single cause or a combination of them. The most common causes that affect operation are listed in the box to the right. Keep reading as we discuss these issues and ways to correct them. Dielectric Grease Corrosion Worn Socket s Improper pin orientation Power Issues Reverse Polarity
Technical Bulletin - Page 2 Dielectric Grease - The LED Enemy In your turn signal housings you will most likely find a greasy substance called dielectric grease. The purpose of this grease is to insulate the bulb contacts and prevent corrosion. Many manufacturers use this in their socket housings. The only drawback to the grease is that it is an insulator, not a conductor. The grease does not conduct electric current very well at all. This environmental condition is especially bad for LEDs. So why do my stock bulbs work just fine with it, you ask? Well, a stock amber 1156 incandescent bulb handles quite a bit of current, 2.15 amps at 13.8 Volts DC to be exact. The high current of the stock bulb is enough to cross the dielectric barrier and light the bulb. When we replace the stock bulb with an LED cluster, we are reducing the current or load quite a bit going through the socket. Our LED turn signal clusters measure just.32 amps at 13.8 volts DC, a difference of almost 2 amps. Positive s Ground This is a Harley-Davidson dual contact 1157 signal socket. Note the locations of the Positive and negative contacts. These should be free of any dielectric grease for LEDs to work properly. The low current draw of the LED cluster is not enough to cross the dielectric barrier, thus, function is inhibited. The result is intermittent or no function from the cluster. So the way we remedy the issue is to remove as much dielectric grease from the housing and contacts as possible. Use a shop rag or towel with your finger and just scrape it out. You should pay close attention to the inside walls of the base as well as the positive contacts (see the photo diagrams of the bulb socket functions). Before re-installing and testing the LED cluster, read below for the next steps. Ground s Socket Corrosion This environmental condition can occur even in the presence of dielectric grease. Over time the socket contacts can become corroded, which can inhibit conductivity. To remedy the issue, even if no visible corrosion is present, use the point end of a flat head screw driver to scrape the positive contacts to ensure a good surface and that it is clear of corrosion and grease. You should also clean the LED cluster base contacts in order to clear off any transferred dielectric grease, as well as any protective film residue left on from the factory. Positive This is a Harley-Davidson Single contact 1156 signal socket. Note the locations of the positive and ground contacts. Because the ground contacts are actually the base walls, it is critical to make sure the inside surfaces are clean as well as the contact.
Technical Bulletin - Page 3 Worn Socket s The last step before reinstalling the LED cluster and testing, we should check the spring tension in the socket. Older bikes may occasionally develop an issue in which the spring that floats the contacts become over-compressed and prevents the socket contacts from making constant contact with the bulb base. You can diagnose this environmental issue by inserting the bulb base in the socket making sure the side pins lock, then pushing down on the base at an angle. If it pushes very easily or seems loose, then the contact spring likely needs some minor adjustment. For Bullet housings only: (see photo right) adjust the ground contact by inserting a small screw driver in behind the ground contact and very lightly prying forward. The trick is not to over extend the contact or spring, use only a small amount of leverage at a time, testing the fitment after each adjustment. Once fitment is better, test for proper operation of the LED Cluster. Ground Harley-Davidson 1157 Dual Socket with adjustment to the ground spring with small screw driver. Everything to Light Up Your Ride
Technical Bulletin - Page 4 Improper Pin Orientation Although most bulb bases are keyed one specific way in the socket, depending on its age and condition, it is possible to misalign the index pins and install incorrectly. All of the bulbs are designed to push in and twist to lock. The first sign that the base is not oriented properly is that it will be very difficult to push in and the base will not lock in place. The second sign would be that the cluster may illuminate full intensity all the time with no turn signal flash, if it works at all. On Dynamic Ringz clusters, the amber center will light up instead of the white ring. The main factor to be aware of for proper fitment is matching the correct index pins with the correct grooves in the socket. Below are the main bulb base types and the location of the index pins. To remedy this fitment issue, verify the correct product is being used for the application as well as making sure the index pins are aligned in the socket properly. 1156 Bayonet Single, 2 index pins Keyed either way 1157 Bayonet Dual, 2 offset index pins Keyed one way Profile Profile 7507 Bayonet Single, 2 offset index pins Keyed one way BAZ-3 Bayonet Dual, 3 offset index pins Keyed one way Pro- Profile
Technical Bulletin - Page 5 Power Issues to the Socket If After all of the previous potential causes have been inspected for and addressed, yet the LED cluster still will not function properly, it is time to troubleshoot the wiring to the turn signal. An automotive 12 Volt test light probe is recommended for easy diagnosis of electrical issues on the bike. These can be purchased at any auto parts retailer or directly from Custom Dynamics. This will make the confirmation of power and ground easy. The way to test for power at the turn signal socket using a test light probe is as follows: 1. attach the connection clamp from the test light to the ground stud or negative battery terminal on the bike. 2. Turn the ignition on. 3. For Single contact sockets: touch the test probe to the [ + ] center contact, the test light should light up. If the light does not light, then touch the test probe to the [ - ] contact, if it lights up - you have a reverse polarity issue (see page 6 for instructions) Pictured above is a 12Volt DC automotive test probe. These can be purchased at any auto parts retailer or directly from Custom Dynamics For Dual Sockets: One [ + ] contact will have constant low intensity running power, thus the test light will light up solid. The other [ + ] contact is the turn signal, when the probe touches the contact, the test light should flash like a turn signal. 5. If the test light did not light up for any of the above, then power is not getting to the socket and further troubleshooting is required by a qualified mechanic or dealer. If power is good at the socket, continue with the ground test. Next, the way to test for good ground at the turn signal socket using a test light probe is as follows: 1. Attach the connection clamp from the test light to the positive battery terminal on the bike. 2. Turn the ignition on. 3. Touch the test light probe to the inside wall of the socket or to the negative contact spring. The test light should light up solid. 4. If the test light did not light up, there is an issue with the ground on the bike and requires further troubleshooting by a qualified mechanic or dealer. If the ground is good, then move on to page 5 to check for Reverse polarity.
Technical Bulletin - Page 6 Reverse Polarity Polarity describes the direction in which electricity will flow. Current flows from the positive pole to the negative pole. Reverse Polarity then is a term that describes an electrical condition in which the positive [ + ] power wire is connected to the terminal on the receptacle intended for the ground [ - ] wire and the ground [ - ] wire is connected to the terminal on the receptacle intended for the positive [ + ] power wire. The wires are, in effect, "reversed." This condition unintentionally occurs at the factory when the single intensity turn signals are installed. So why does this not matter when we use incandescent bulbs? Well, incandescent bulbs are different from LED clusters in the respect that electricity can flow either way through the them, positive to negative or vice versa. An LED cluster will only let electricity flow one way through, Positive to negative. When we have confirmed that there is power all the way to the turn signal socket, as well as confirmed that the LED cluster lights up, then reverse polarity is usually the issue. To remedy this condition, we need to confirm it by using a test light probe, then re-wire the cluster. Follow the instructions below. 1. attach the connection clamp from the test light to a ground stud or negative battery terminal on the bike. 2. Turn the ignition on. 3. Touch the test probe to the [ + ] center contact, the test would normally light up, but since we are looking for reverse polarity, we should not have any current here. 4. Now touch the test probe to the [ - ] ground wall contact. The test light should come on. This is confirmation of reverse polarity. 5. Turn Ignition off. 6. Cut both wires on the 1156 cluster halfway between the connector base and the cluster. 7. Next, you will need 2 pieces of heat shrink tubing to cover the connections, a soldering iron and a heat gun. 8. Strip back the insulation on both ends of wires, then twist together as follows: - The connector bases end black wire will attach to the colored wire on the cluster - The connector base end colored wire will attach to the Black wire on the cluster 9. Apply solder to the connections. 10. Cover solder connections with heat shrink tubing and use the heat gun to shrink the tubing. 11. Re-install the cluster and test for function on the bike. Colored Wire Colored Wire Black Wire Black Wire = Solder Points