Vehicles

ts250 - troubleshooting faulty turn signals and investigating faulty oil injector

The bike has no turn signals on the front and the ones in back don't work. It was time to fix the rear ones. I set about reviewing the electrical system, armed with a color wiring diagram in my new service manual (very nice). 

The electrical system on the bike is extremely simple. It is also mostly original which is pretty impressive. I did find one wire run from the coil mounting braket up to the headlight assembly where it tied into ground. This wire was not original and not in the wiring diagram. I removed it without any change to the functioning of the motorcycle. My guess a previous owner was have some problem with hesitation and thought the coil's existing ground may not be good so he added another one.

The problem with the turn signals is in the signal assembly itself. They are corroded and rusted out. They just need to be replaced, pure and simple. The wiring from the turn signal switch all the way back to the signals themselves is good, thankfully. 

Initially I thought about giving this old bike a break and getting LED turn signals along with a new LED friendly turn signal relay. This would put the eletrical system under much less stress. Then I realized that no one makes 6 volt LED turn signals as a complete assembly. I would have to buy an existing turn signal, remove the bulbs, and replace them with 6 volt LEDs shaped like a bulb. This is going to get expensive. I was hoping to skip the middle man, save a few bucks, and get signals hard wired for LEDs but those only exist in the standard 12 volt variety.

Oh well, I won't worry about signaling just yet. I have bigger things to attend to first like getting it registered.

Pictures

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where the front turn signals should be
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extra ground wire run to right side of coil, not necessary and is just confusing
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removed previous owners additional wire, no change to bikes performance
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thats the entire wiring diagram! that would cover the motorized windshield circuit on my 2007 FJR
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I labeled the wires that will go to the future front turn signals
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just documenting what is under the tank
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cci oil injection pump visible just above chain, it has a throttle cable going to it
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cci cover plate removed, everything seems intact, no obvious issues
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throttle cable still connected, its driven off a gear on the back side
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this thing should work, I will replace the oil reservoir and see if it pumps oil
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lines from cci pump go to crank bearings (lower) and cylinder (upper)
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chain guard is about to fall off, rubber mounting grommet has disintegrated

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