Headlight up-grade - 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 11 Old 10-03-2006, 05:42 PM Thread Starter
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Headlight up-grade

I have heard a lot of talk about Tamy's www.totallywiredcycles.com improved headlight wiring harness. I had a couple relays laying around, and I always have some extra wire, so I decided I would make a new harness for my A18. I ran two wires from the battery to the dash I had made. I connected three fuses to the hot,(pos) wire. On the other wire from two of the fuses I connected a relay. From the relay I put a wire to the plug for the headlight. I cut the plug off the stock wiring harness, took the connectors out of the plug and soldered the wires from the relay to them and then put them back into the plug. I took the stock wires and soldered them to the relay. I took all the ground wires, 1 from the headlight, 1 from the battery, 1 from the stock wires, and 3 from the relays,( the 3rd one is for the 12v power socket for the cell phone charger.) and connected them all to the frame of the bike.

Now I have upgraded the wires to the headlght, running a wire from the battery to a fuse to a realy,(one for the low beam and one for the high beam)to the headlight. Using the stock wires to energize the relay. The results are pretty impressive.

I compaired my A18 amd Marcia's A12 side by side in the garage shinning both headlights on the garage door at night with the lights in the garage off. That is where my helper saved the day. Imagine turning off the lights in the garage and trying to walk over to a motorcycle and find the key in total darkness. Thanks Jordyn!!!!

The A18 with the upgraded wires is on the right side. I DO HAVE AN 80/100 BULB in the A18 and the A12 has the 55/60 stock bulb. So there is some diffrence there too.Top picture is with the low beam on.

This one is with the high beam on.

I got these driving lights from Ruby and Jordyn for my birthday, and the ones I had mounted lower on the forks kept blowing , so I made a bracket and mounted these.

And this is what the garage door looked like with the driving lights on. Without the lights from the bikes the garage is total darkness.

Now I have to make the changes to Marcia's A12, because I want her bike to be safer, or as safe as mine. I think the LED brake light will be the next item on the list.
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post #2 of 11 Old 10-03-2006, 05:47 PM
 
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Sweet... where did you get those driving lights and are they easy to wire up?
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post #3 of 11 Old 10-03-2006, 06:03 PM
 
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Nice setup Daddyjoe. I've got Piaa running lights mounted on my lower legs.I had heard about some trouble mounting them that way but I haven't had any problems with them yet. Knock on wood. I mainly use mine in town so I can be seen a little better. Or when driving through deer country at night. They really light things up.
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post #4 of 11 Old 10-03-2006, 08:47 PM
 
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I got Tammy's harness and really like it. It is nice to see the side by side on the upgrade, thanks...Doug
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post #5 of 11 Old 10-03-2006, 08:47 PM Thread Starter
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The lights was a gift, if I had to guess I would say they bought them at wally world.
As for the wiring, they came with a harness, I just added the relay and a diffrent switch.
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post #6 of 11 Old 10-03-2006, 08:49 PM Thread Starter
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I had mine mounted on the forks where the reflecters are, but kept blowing bulbs so I moved them up.
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post #7 of 11 Old 10-04-2006, 11:27 AM
 
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Daddyjoe,

I really like those driving lights you have. Pretty snazzy. Nice place to mount them also!



Great minds do think alike!
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post #8 of 11 Old 10-05-2006, 05:26 AM
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Quote:
Originally Posted by Daddyjoe
I had mine mounted on the forks where the reflecters are, but kept blowing bulbs so I moved them up.
Was it the vibes blowing the bulbs? I had intended to do the same, but this is the first I have heard of the bulbs blowing. Dang.

Life is a mortal adventure. Don't avoid all the risks.

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1998 Honda Valkyrie Tourer
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post #9 of 11 Old 10-05-2006, 08:16 AM Thread Starter
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I really don't know what blew the bulbs, I see three things as possibilitys,
1)Cheap lights
2)Too much vibs
3) Water, (most likely) they catch a lot of water if it is raining, and a lot from splashes.


Quote:
Marty


Daddyjoe,

I really like those driving lights you have. Pretty snazzy. Nice place to mount them also!

I seen where some one is making and selling a bracket for the Strom almost like the one I made for the KLR. I might have to make a few this winter.
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post #10 of 11 Old 10-05-2006, 09:59 AM
 
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Uh . . . . put me down for one!
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