Installing turn signals (2021 zForce 800, 2022 zForce 500 and similar)

Started by aganarr, June 19, 2023, 01:19:31 AM

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aganarr

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Posts: 50
2022 z500 trail, 2021 z800 trail & 2010 z6
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aganarr
Full MemberPosts: 50
I wanted to document the installation of turn signals on my new (for me) 2021 zForce 800 trail.  With the 2022 zForce 500 trail the wire colors I tapped into were the same.

Here's the turn signal kit I used...
https://www.amazon.com/gp/product/B09XQKR6RS/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Also these will make things a lot cleaner when it comes to the custom wire harness...
https://www.amazon.com/gp/product/B01F54PFLE/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B07VX671SM/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B08DLK7DRH/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B07WWWPR2X/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

You'll need to access/locate a few things first.  In the front of the machine near the radiator are the factory plugs for the signal lights (see pic 'Front sockets').  These are what you will use to power the front signals.  If you are fortunate enough to acquire a brand new unit the matching plugs for the lights themselves will be included.  Under the dash display you'll find a plug (or two) that have orange, blue, green, grey and black/brown wires.  This is the socket used to access the factory wiring with the installed switch and relay.  Then in the rear of the machine, visible thru a space in the back panel, you can get access to another plug with orange, blue, green, black/brown, green/yellow and brown wires (see pic 'Rear socket').  This is where you'll tap into the factory wiring to power the rear turn signals as well as have access to the brake signal in case you have a whip light set that supports additional lighting features.  Such as...
https://www.amazon.com/gp/product/B0995YPXCZ/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

I then modified the harness from the signal kit.  Since it can be powered from the black/brown 12v and green ground wires there's no need to run power all the way from the battery (see pic 'Original and modified turn signals).  On the SxS end I cut off the original plug under the dash and installed the other half of the waterproof 4 pin socket so that the signal right part of the switch goes to the blue wire, left part to orange, ground to green and power to black/brown (see pic 'Console socket modified).

For the front of the machine I changed the plugs to the waterproof 2 pin ones from Amazon to connect the front lights (see pic 'Front signals with sockets').  You will probably need to remove at least a few of the plastic pins to get enough wiggle room to access the fender in such a way that a 3/4" hole can be drilled to install the signals.

For the rear of the machine I ended up taking off most of the plastic panels.  I was doing a full cleaning plus valve adjust and compression test anyway after I got the machine so I had full access to all wiring and mounting points.  You can get away with NOT taking off ANY of the pieces, you'll just need to be a bit more clever/patient when connecting and installing everything.  Again, I just cut off the existing plug and modified the harness to accept the additional lights (see pic 'Rear signal harness).  This (as mentioned before) is the step you'd also use to install a light whip that you would want to control with either the power from key on or power from headlight/running light wires and/or light using the left/right signal or brake wires.  Again a 3/4 hole is made for any signal lights installed.

I would most certainly recommend testing everything each step of the way starting with the relay/switch under the dash.  You'll be able to see the indicators light on the dash with the activation of the switch (see pic 'Console signals factory look').  This will tell you right away if there are any problems with the wiring.  Then, do the same after connecting each light BEFORE fully installing it onto the machine as this will make undoing to correct any mistakes far easier. 

The project can be completed without any of the extra plugs, everything will just need to be hard wired.
2022 zForce 500 Trail [~800 miles]
Falcon Ridge enclosure | 4" LED flood lights
Pack A, B

2021 zForce 800 trail [~1300 miles]
3 Star Industry rear windshield
27" ITP Mud Lite XTR tires 
Pack A, B, C

2010 zForce 600 [~800 miles]
3 Star Industry enclosure | 2" rear lift kit | Boss Audio 450w ATV/UTV speakers | Custom Spectre air intake
Pack A, C

Pack A: LED light whips, Rock lights, Overhead storage
Pack B: SuperATV flip up windshield, 26" BOSS Audio sound bar, UNI filter, 2" rear wheel spacers
Pack C: 4" LED rear flood lights, 42" front light bar, Extended fender flares

NMKawierider

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Posts: 12,593
2015 ZForce 800 53 (Trail)
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NMKawierider
Global ModeratorGuruPosts: 12,593
Great write-up. Thanks for posting.
2015 Z Force 800 53/Trail EPS
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage |7- 9.7" GPS Systems | Bandit Springs Rear & Gen-3 Shocks Front | Cage Chop Mod

My Videos On YouTube

TheHermit

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Senior Member
Posts: 130
2022 Zforce 800 Trail Yondering Edition
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TheHermit
Senior MemberPosts: 130
Awesome detailed post! Thanx for sharing!  :)
2022 Zforce 800 Trail Yondering Edition