Kawasaki 2021 Ninja 650 rear turn signal base

Description

Rear turn signal base for a 2021 Kawasaki Ninja 650 OEM fender. The OEM base has a rubber mount – over time it gets brittle and breaks at the flange. To replace it with a factory part you have to buy the whole light assembly – rather than doing this I decided to design a 3D-printed part for just the base part. Hardware needed: M3 x 12 bolt and nut. Print the mounting plate, and the left or right side base as needed in PETG. Print the strain relief in TPU. If you don’t have TPU, you could use rubber bands, although I’m not sure how this would hold up over time. Two or three size 19 rubber bands, each looped 3x over the mounting plate would work well. You could also use an O-ring, or anything else that is elastic and will fill in the gap. The assembly pic shows rubber bands being used. For my final fix, I used a TPU strain relief. The strain relief allows for a bit of movement in the assembly (the fit between the mounting plate and fender cutout is purposely made to be loose), so if something brushes up against the light, it should reduce stress on the printed parts and fender. Assembly steps: 1. Drill through the bridged holes in the printed base part. 10mm (25/64”) for the large hole, 6.5mm (1/4”) for the smaller hole, and 3.5mm (1/8”) for the hole at the bottom. (I don’t like to use supports where possible in my designs – and an unsupported hole within a bridged area does not print well.) 2. Insert an M3 nut into the slot in the bottom of the printed base. Line it up with the 3.5mm hole. 3. Cut off the connector from the factory light assembly in the plastic loom part area. I like to do this somewhat near the connector end. SAVE THE CONNECTOR! 4. Unscrew the metal plate in the factory base – this will allow you to slide the base off the light assembly. NOTE: Hold the plastic loom in place against its wiring as you pull off the base, as the loom will no longer be secured. If the loom gets separated from the wires, it’ll be a pain to put it back (as me how I know LOL). SAVE THE METAL PLATE AND ITS SCREW! 5. Install the printed base onto the light assembly. The wiring loom runs through the 6.5 mm hole in the base, and through the larger hole in the metal plate. Make sure the orientation of the metal plate is correct. Use the OEM screw to secure the base to the light assembly through the metal plate. 6. Install the strain relief (TPU or rubber bands) around the printed mounting plate, and feed the wiring loom through the opening. Make sure the orientation is correct (the side of the mounting plate with the slot faces toward the bottom of the base). See the assembly pic for reference. 7. Reattach the OEM connector to the end of the wires using your connection type of choice. I ended up soldering mine. 8. Feed the wiring connector and mounting plate through the fender piece from the outside, and then use an M3x12 bolt to attach the mounting plate to the light base. The M3 bolt should engage with the nut in the base. The “F” on the mounting plate should face towards the front of the bike.

Statistics

Category

Tags