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Hazards and Passing Lights on Left Handle Switch

dmonkey

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Jul 4, 2021
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The Honda CT125 doesn't come with hazard lights / four-way flashers / park-anywhere lights and that's a feature I find myself wanting to make use of on occasion for temporary parking or for extra visibility.

* Check your local laws before using hazard lights. In many states there are few situations where it's legal to use hazards while a vehicle is in motion.

The kit I went with for this is: KITACO L-handle Switch, Part No.: 756-1470100

This kit is plug-and-play in terms of electrical wiring, but does require drilling a hole in the handlebar for aligning the switch assembly. The left and right handle switch assemblies each have an alignment peg on the inside of them that keeps their position fixed to a hole drilled on each side of the handlebar. The aftermarket switch assembly has that mounting peg at a different position where it doesn't line up with the hole in the OEM handlebar, so a new hole needs to be drilled.

Here's what came in the kit. Next to the plug end is a rectifier that Kitaco have added. It's labeled "MM8" and from what I can find seems to be a common Honda motorcycle electrical component with Honda P/N: 31700-MM8-610. Fit and finish on the switch assembly is nice and seems OEM quality. The wiring looks like they modified an existing product and then cleaned it up with electrical tape on both ends, but it looks like they did a good job of it and the wrapping is tight with no peeling.
hazards1.jpg

Kitaco provide both Japanese and English instructions as PDF downloads on their website. A drill template was included, but I misplaced it so I followed the instructions for using Adobe Acrobat to print with the "actual size" scale printing option selected.

For the installation I followed along with this video for the most part:

The plug for the left switch assembly is accessible tucked to the inside of the left fork tube. The plug has a rubber boot on it that slides over a metal tab for cable management, so you will want to slide it off of that tab to have enough room to work with the cable. Once the cable is disconnected it can be fed upward where the plug just fits past the meter stay bracket. Take your time with feeding the cable up, but if you have trouble with it you could remove the headlight and then the left side headlight bracket to get better access to the plug.
hazards2.jpg
Remove the OEM left switch assembly by unscrewing the two Phillips screws from the back side of it.

My CT125 has Barkbuster hand guards installed and they were going to be in the way for drilling the handlebar so I partially removed the guard on the left side. If your CT125 has the stock bar end weights installed, Kitaco recommend removing the left side one so you don't drill into it.
hazards3.jpg

Drill template aligned over original hole and taped in place.
hazards4.jpg

I used an automatic center punch to dimple where the new hole will be drilled in the handlebar, cleaned the hole with a deburring tool, and then ran a shop vac hose to the open bar end to try to remove the swarf.
hazards8.jpg

Some LSL handlebars I bought years ago included this drill jig for 7/8" or 22mm bars which I used. A jig isn't necessary but it makes it a lot harder to mess up. Without one just take your time, position the bar so you can get the right angle on it, use a punch, and drill a pilot hole. I looked up what it costs to buy just that LSL drill jig on its own today and it's not worth it especially with shipping, if you're looking to add a specialty tool to your collection there are cheaper AND more functional options that double as a saw guide.
hazards5.jpg

Hardware stores in the USA often have a poor assortment of metric drill bits outside of tap sets, so if you don't have one on hand it might be easiest to buy a 5mm bit online. Or if you live near a Menards I've found that they're carried under the Menards' Performax brand. I didn't check a 3/16" to see if it would be too small or 13/64" if it would be too big, but if you have those on hand you could measure the alignment peg and find out.
hazards6.jpg

New alignment peg hole drilled and deburred.
hazards7.jpg

Kitaco left switch mounted. Note the added hazards button as well as the "PASS" option on the dimmer switch for all those times you'll be passing vehicles with less donkey power... or more likely just signaling a hazard to oncoming vehicles.
hazards9.jpg

At this point I tested the hazards and the pass/high beam and everything worked. I don't know why Kitaco included the replacement turn signal relay, as it works without it. I contacted Kitaco to ask this question and will post an update here if they answer it. [Kitaco responded, reply in the comment after this post.] The hazard signal basically overrides the turn signal. By that I mean if you have a turn signal on and then turn on the hazards, the hazards take precedent and all four indicators will flash in unison. The turn signal cancel does not cancel the hazards, only pressing the hazard switch a second time will cancel them, and the turn signals will resume where you left them once the hazards are canceled, unless you canceled the turn signal while the hazards were on. When the hazards are on, the instrument cluster indicates it by blinking the turn signal indicator light on the display.

Continued in comment for turn signal relay replacement.
 
Last edited:

dmonkey

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I decided to replace the turn signal relay even though it didn't seem necessary for the hazards to function. Kitaco included it on a CT125 specific kit, so installing it seemed like the safe thing to do.
The print instructions are lacking in detail when it comes to replacing the relay, and the YouTube video shows you how to access it and then warns not to do it the way they show and says the rear carrier should be removed first. I decided to try replacing it without removing the rear carrier, and that worked with the catches being that it was tricky to remove the plastic body panel behind the fuel tank and I ended up scuffing it, and it's a tight squeeze to reach your hand in and fish the relay out.

Plastic body panel behind the fuel tank removed and the turn signal flasher relay circled.
relay (1).jpg

Here's a dirty close up. The relay has a rubber boot around it, and that rubber boot clips onto a retaining tab behind it. The rubber boot needed to be wiggled off the retaining tab to pull the cable out, and then the boot could be pulled down from the relay and the release clip pressed to unplug the OEM relay.
relay (2).jpg

Side by side of the OEM turn signal relay (Honda P/N: 38301-KZZ-J01, Mitsuba FR36-001) and the replacement one provided by Kitaco (CL36-001). The listed specs are the same other than wattage.
relay (3).jpg

This is the female plug end on the wiring harness that the relay plugs into.
relay (4).jpg

The Kitaco relay came with a rubber attachment installed to the clip that could hold it in place to the clip that retains the relay on the bike, but I reused the OEM rubber boot that was already in place on the wiring harness as it looks like it offers some weather protection. The bottom of the Kitaco relay is sealed. the OEM one is just clipped in place and not sealed. More on that later.
relay (5).jpg

Kitaco relay in the factory rubber boot.
relay (6).jpg

I spent a few minutes contorting my hand and fighting to get the rubber boot back in place on its cable management retaining clip before giving up on doing that without some help. A spray of silicone lubricant and it slid right back into place without any more fuss. I sprayed some more on the plastic tabs of the plastic body panel before reinstalling it as well. If you're ever fighting the rubber snorkel hose on the air box trying to get it back into place, this is the easy solution as well!
relay (7).jpg

For reinstalling the plastic body panel it's a tight fit with the rear carrier in place and I learned my lesson scuffing it on removal, so I covered it for reinstallation.
relay (8).jpg

Here's the little scuff mark from where it rubbed on the rear carrier on removal. Not something that's really visible, especially when the seat is latched in place. If I were to do it again I'd do the same thing and just put a piece of plastic, tape, or shop towel over it before removal. Beats taking the time to remove the rear carrier, especially with a top case installed.
relay (9).jpg

Here is the OEM turn signal relay which came apart after I removed it, but also easily snaps back together. I didn't like how easily this came apart once it was removed from the rubber boot. I understand that it may be intentionally vented, but it could have been epoxied together.
relay (10).jpg

If the Kitaco relay ever needs to be replaced it is Kitaco P/N: 755-0400940 and available on Webike and other sites.

And the final show:


Update - Response from Kitaco regarding the turn signal relay:

Thank you for your message.
Since this product adds a hazard function, the normal relay may fail due to overload.
Please replace it with the supplied relay.
 
Last edited:

LittleWing

Member
Joined
Jun 15, 2023
Messages
35
Dmonkey
Another Great Review..
Very well documented ..
Your writing ability is amazing ...
And the photos/video nicely show all of us
what can, and should be done to our fun set of wheels.. Keep up the great posts...
LittleWing
 
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