The Official Driving lights thread!! - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 19 Old 09-30-2006, 09:29 PM Thread Starter
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The Official Driving lights thread!!

I wanted to be like biker, so I chose a similar title: :wink: :wink:


This thread is dedicated to Roland, who helped me through the project.

I purchased off road driving lights at Wally World. The smaller version of the two. they come stock with 55w bulbs. I replaced the bubls with PIAA 35 watts. PIAA is gaurnteed to burn 35w and not more and are less likely to blow.

Using cardboard, I mocked up this shape. the holes line up with the holes for the fender. I used 3/26 alum for weight savings and strength. 13" long. I took one inch off each end and bent them downward to protect the lights from damage.



Then I went to a local welding shop, took them the cardboard. they cut the shape and supplied the alum for 20 duckets. not bad :mrgreen: took the fender of and remounted it with the alum bracket. the bolt threads were long enough, not to purchase new ones. I mounted the lights using nylon locking nuts. placed them to the outer edge so they can be turned and pivoted. before mounted I uesed very fine steel wool to polish it up. perfect.


another pic


I wired the lights with a relay and switch. the switch is mounted on a dash I stoll from AIC_Rooster.


And finally I removed the front fairing so can wire it all up cleanly. using shrink tubbing and everything.
the wiring diagram is one that Roland gave me. I cleaned it up for him and here it is for all to enjoy.


The lights have stood the test of four drops off roading so far. the bracket is the perfect size and the lights turn with the wheel that greatly improves vision on the twisties at night.

A huge thanks to Roland for the help and AIC_Rooster for posting his dash project. (other place). I couldnt have done without you guys.


enjoy fellas!!

Steve - Tazmanian Devil
00 KLR
PTB - FTM - KTF
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post #2 of 19 Old 09-30-2006, 10:25 PM
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Nice setup.

I guess I have an advantage when it comes to the alluminum. I know the owner of a recycling shop and he lets me go through and pick out anything I want. He charges me a few cents more than he will get when he scraps it out, so I get it pretty cheap. I did mine almost the same way you did yours.


Why do you have the ends turned down?
If that pic doesn't show someone will have to put up some instructions. Please!!!
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post #3 of 19 Old 09-30-2006, 11:24 PM Thread Starter
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you pic shows, its just small.

I like your set up as well. very similar. what material did you use.

I turned the ends down just to protect the lights a little better. in the event something whant to hit the lights maybee the bracket will get hit first.

thanks

Steve - Tazmanian Devil
00 KLR
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post #4 of 19 Old 10-01-2006, 12:28 AM
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It is a alluminum plate about 3/16" thick, mounted between the fender and the lower tripple. When I put the nerf bars on I had to cut about 1" off each side to allow the lights and bracket to clear the nerf bars. The lights are now closer to the fender, but still the same setup.
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post #5 of 19 Old 10-02-2006, 12:00 PM
 
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You lost me on the wiring diagram... put together a kit and I'll buy if from you!
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post #6 of 19 Old 10-02-2006, 04:48 PM Thread Starter
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I thought mods new it all. :lol: :lol:

I think a kit would be great. but not sure it would be easy. my friend in LA as asked me to put one together for him. I may make two. ill let you know if I do.

Steve - Tazmanian Devil
00 KLR
PTB - FTM - KTF
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post #7 of 19 Old 10-02-2006, 04:57 PM
 
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I'm electrically retarded. Sorry... but I do know everything else. The benefits to knowing almost everything is also knowing when to defer to others more knowledgeable than yourself.
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post #8 of 19 Old 10-03-2006, 09:16 PM
 
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Quote:
Originally Posted by Biker Scout
I'm electrically retarded. Sorry... but I do know everything else.
In that case....What is the airspeed velocity of an unladen swallow?

:lol: :lol: :lol: ...Doug :twisted:
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post #9 of 19 Old 10-04-2006, 11:59 AM
 
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Is that an African or European Swallow?

http://www.style.org/unladenswallow/
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post #10 of 19 Old 10-05-2006, 01:52 AM
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I got the same lights from wally world, but opted to put a piece of aluminium as a backing plate. yours look really nice beside the fender. Here's how I did it. I would think they would be les prone to getting snagged under the fairing.

2002 KLR 650
1978 RD 400 vintage racer
"I'm flat out like a lizard drinking"
Thanks Steve, you will be missed.
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