How to install ultra bright LEDs in your instrument cluster

How to install ultra bright LEDs in your instrument cluster

The following is a step-by-step guide that will instruct you how to replace the incandescent bulbs in your Chetak's instrument cluster with ultra bright LEDs. This is a simple procedure that will take you around 30 minutes to complete (give or take).

Materials Needed

LEDS

To perform this modification, you will need the following LEDs:

2 WLED 4 - Green
1 WLED 4 - Blue
1 WLED 5 - White
1 WLED 1 - Blue
1 WLED 1 - White

These LEDs can be purchased from http://www.superbrightleds.com/cgi-bin/store/commerce.cgi?product=CAR. Click the link, then go to the second page and you will find the LEDs you need there. The total price for this mod is approximately $20.00

You can experiment with different color variations, but the LEDs outlined above will give you a good basis from which to start, and have proven to be successful with others' scooters.

Tools:

You will need the following tools to perform this mod:

1 flat-bladed screwdriver
1 #6 hex (allen wrench)

Procedure

Remove the mirrors using the #6 hex.

Remove the remaining four screws using the flat-bladed screwdriver.

The following image shows the locations of this hardware:

Unscrew the fastener that connects the speedometer cable to the speedometer.

Remove the light fixture from its housing.

Remove the light from the light fixture.

Replace the light with the appropriate LED. Test each LED as you install it by turning on your Chetak's ignition and verifying that the LED is illuminating. Unlike the incandescent lights, the LEDs are polarized. If the LED does not illuminate, turn it around in the housing.

A diagram of where to install the LEDs is provided below.

To complete this procedure, re-attach the speedometer cable to the speedometer, fasten the headset with the four flat-bladed screws that you removed, and re-install the mirrors.

Results

Below are some images of my instrument cluster after having installed LEDs.

Last edited by danman1178 on Wed Jan 23, 2008 3:09 pm; edited 1 time in total

Fantastic how-to Dan!

Did you paint your scoot?

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It was just an innocent gas pump fight...who would know it could be dangerous?

That's badass.

After my recent success pulling the tank, I'm gearing up to do some simple mods and this one seems like a winner.

Have you noticed if the brighter lights are distracting at night?

-B

I can't take credit.... matty_x Made the How To - he asked me to move it from another post into a new one...and I could not figure it out...so I just cut a pasted it....

???

	Quote:
	Have you noticed if the brighter lights are distracting at night?

No way. I find the brighter lights to be much more readable than the stock both in the daytime and at night, and I'm not distracted by them at all.

I've got a stereo on my Bajaj that I play real loud so I can hear it over the POC pipe. As such, I can't really hear the "beep beep beep" of the turn signals. The bright lights help draw my attention to when I forget to disengage the signal.

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The "X" stands for ex-Chetak owner.

I've been wondering about LED clusters as a headlight replacement- do you know if there's anything bright enough and power-friendly enough yet to do that duty?

-B

I was hoping to replace the LEDs, but I'm a bit confused on which LEDs to get:

The post says:
--------------------------------------------
To perform this modification, you will need the following LEDs:

2 WLED 4 - Green
1 WLED 4 - Blue
1 WLED 5 - White
1 WLED 1 - Blue
1 WLED 1 - White
-----------------------------------------------

But I only see the Green and Blue LED 4s on the stated webpage. I assume the number after the LED means its a different size, so that means WLED 5 and WLED 1 arent on the webpage.

Can anyone clarify? Am I missing something?

looks like maybe they have changed their item description/listings since this was posted?
I just went to purchase my own and am also confused.

which bulbs should be purchased, from page 2?
I see the: WLED-x4 LED bulb
12VDC 4-LED Wedge Base Bulb (194/168 type)

or the:
WLED-x-x LED bulb
12VDC 1-LED Wedge Base Bulb (194/168 type) with 90 or 120 degree Wide Viewing Angle LED
Select LED Color and Viewing Angle

Ross

These LEDs are on the SECOND page as of June 21, 2008.

From the above image, buy one blue and one white WLED 1 (the top picture)

Buy one blue and two green WLED 4 (the bottom picture)

This LED is on the FIRST page as of June 21, 2008.

Buy one white WLED 5.

_________________
The "X" stands for ex-Chetak owner.

Thanks Matty! I ordered them with confidence tonight....
page shots make a world of difference, we'll see if the led's make the dash add the same...

Ross

You Da Man, Matty!

Hopefully I can get this done soon and stop riding around town with my blinker going.

I keep forgetting to shut it off since I cant see them, pissing off opposing drivers, I'm sure.

thanks for the help Matty and a great original write up. Just did mine, if you're mechanically inclined, it's pretty easy.
I was also able to take the plastic gauge cover off and rub out some light scratches that were inside.

I also tightened down all screws and bolts that I saw and lubed the throttle housing/clutch and cables.

A nice upgrade, I can see them better, but still can't see them in sunlight with my dark goggles on (can't see turnsignals). I hooked the turn signal beeper back up and with two pieces of tape on top, it's not too bad.

Ross

I'm just curious...
Has anyone tried using L.E.D.s all of the same color?
I am thinking of using all red lights...
Red is easy on the eyes and I'm thinking they would look
great on the speedo...

Thoughts?.... Opinions?

Muchos Machos

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Happy Trails,

Cowboydoug

I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...

Yes, I tried red.

No it didn't work.

_________________
The "X" stands for ex-Chetak owner.

Will this work for the Legend?

With a shout out to Matty_X and AverageJoe who talked me through this with useful tips. you guys are awesome!

It started out as a good evenings project that my 5 year old helped with and took 3 more sessions for me to get this right. So here's what I learned.

1. Detach the speedo cable housing at the front wheel hub. That gives you more play in detaching and re-attaching the speedo cable.
2. The speedo cable is supposed to slide in and out of its housing a lot. Don't be alarmed, lube it before reassembling everything.
3. The flatheads that hold the instrument panel housing in place are set in deep. A Black and Decker Pivot drill with an LED lighting (About $20, target) heled a whole heck of a lot. My 5 year old shouldn't have learned all those bad words from me =)
4. Don't get the cable cluster that comes off the LEDs physically impede with your throttle play - move them where they don't, there's plenty of space in there. I made this mistake and had to do a 20 min redo to move the cables out of the pay. Not the end of the world, but boy was it a slow test ride!
5. My tip for aligning the mirrors: I slide the #6 allen into the bottom, slide the mirror over the top, and then hold it in my left, pick up the nut on the allen after I slide it out and re-thread. The alignment was a little annoying because when I didn't get it right the mirrors would spin around their axes. But with this little trick it went a lot faster than the first two times.

Yes there is hope for even the mechanically declined (moi) -ask around here, and keep at it!

_________________
1986-1990 - Bajaj Cub (2 Stroke Chetak)
2008 - present - Bajaj Chetak
And Oh, BTW, its "chey-thuck" not "chee-tack" darn it!

I just finished installing my LEDs following the steps lined out in this thread.
All I can say is "Wow, what a difference!". It was super easy to do and didn't take much time at all.

I really appreciate you guys taking the time to document the 'How-To's' in this forum. It really helps out newbies like me!

THANK YOU!

oh, can anyone tell me how to Reconnect my beeper? just in case I still don't remember to turn off my signals Smile

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02 Bajaj Chetak
04 Aprilia Mojito Custom 150
01 Ducati Monster Chromo 900
01 Buell Blast 500
90 Honda GB500

Update on the Legend. These bulbs will NOT work with the Legend. The Legend Bulbs are miniature bayonet type, which the same website does sell.

A word of warning: I blew out three LED bulbs (the three engaged at the time, both whites and a neutral). I'm not positive how, but I think it was from turning on the scooter while trickle charging the battery. Not a big deal and bulbs aren't expensive, but it's something to avoid.

	Matt G wrote:
	A word of warning: I blew out three LED bulbs (the three engaged at the time, both whites and a neutral). I'm not positive how, but I think it was from turning on the scooter while trickle charging the battery. Not a big deal and bulbs aren't expensive, but it's something to avoid.

Manuals always say to disconnect your battery from the vehicle when charging, probably to prevent this from happening. I know- who really does what a manual says? Laughing

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It was just an innocent gas pump fight...who would know it could be dangerous?

You should disconnect the battery any time you are farkling with wires or bulbs. It's all too easy to short two things together, especially if you have a longish stick of metal in your hands.

Same with battery charging, and make darn sure you have no wiring issues if you intend to trickle charge.

Always disconnect the ground side of battery first. I don't know how many times I've shorted a wrench by starting to disconnect the hot lead first. Confused

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"I see a big market for designer tin foil head gear..."

"Grow up and stop posting like a 14th Century Vatican Flat Earth Zealot."

I got my LEDs and I'm doing this mod today, along with my oil change and headlamp swap-out.

LEDs' - check
Flat screwdriver - check
#6 Hex - check
(willing Chetak) - (check) I'll speak for her, I know she wants it!
20-50 4T oil - check
empty Sriracha bottle - check
6-7 cans cold PBR - check

Don't time me, boys, I took the whole day off so there's no rush! :p

_________________
2003 Bajaj Chetak
2007 Genuine Buddy 125

	Quote:
	I got my LEDs and I'm doing this mod today, along with my oil change and headlamp swap-out. LEDs' - check Flat screwdriver - check #6 Hex - check (willing Chetak) - (check) I'll speak for her, I know she wants it! 20-50 4T oil - check empty Sriracha bottle - check 6-7 cans cold PBR - check Don't time me, boys, I took the whole day off so there's no rush! :p

Cool! So, how'd it go???

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2005 Chetak

Great! It took me 30 min to do my oil change - found a great solution to the filling issue... Go to Sally Beauty Supply, get a plastic applicator bottle used for hair color, they are graduated up to 400ml so 2 1/2 fills and I'm good... Works better than the Sriracha bottle as it's very flexible, long nozzle, made for squeezing the contents out, PERFECT for motor oil. 2 beers...
Got the head lamp out, drove to O'Reilly, got an H4 bulb, haven't driven at night yet so I can't report if this one did the trick, it was $23.
Got the handlebar cluster done, easy peasy, so freeking easy... 3 beers into it and I'm thinking this is TOO easy...
The speedo cable was easy for me as well because I could get my fingers in between the top and bottom to undo it and put it back, whereas I'm sure you fellas often have to find a tool to do this, one of the advantages of being a girl, I guess.
That was last Friday. Took it to the car wash, went to lunch after, drove all around, seem to see the turn signals clearly in daylight now, but it started to rain and snow this week, and so I hadn't had a chance to get out in the dark to test the headlight still. Tomorrow it will be 50's again, and sunny, and I'll let you know driving home in the dark at 5pm after work... if this isn't the best headlamp I'll take it back, spend a little more, get a super bright one.

***Update!***
Rode last night, couldn't take it any longer, 40 degrees, froze my ass but oh well... The difference is Night and Day, literally. Everyone should do these mods! Smile

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2003 Bajaj Chetak
2007 Genuine Buddy 125