Some old Gen 1 wiring - 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 9 Old 11-16-2013, 10:45 PM Thread Starter
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Some old Gen 1 wiring

Spent a bit of time cleaning up the rear wiring on KLR#2 (1997) and thought someone might like a chuckle at the condition.

The connectors were all corroded and dirty. The boots for the tail light were badly chewed away by flying gravel so made the following modifications:

1) Removed both rear signal lights and extended the lead wires so allow them to plug into the harness under the seat, near the sub-harness plug.

2) Converted from the smaller pin plugs to 2.5 mm to 4 mm bullets.

3) Covered the wires by plastic conduit.

That should be much more robust and hopefully last a few years.

Some photos of the nasty connectors.

FWIW, a $20.00 Harbor Freight hand held sand blaster is a wonder for cleaning corroded bulb sockets and connectors. It certainly beats trying to use sandpaper.

Last edited by Normk; 11-30-2013 at 12:48 AM.
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post #2 of 9 Old 11-17-2013, 08:56 AM
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Sound maintenance, indeed!

Good on ya, Normk.
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post #3 of 9 Old 11-17-2013, 09:55 AM
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I checked out that small, portable sandblaster you mentioned, Normk: quite an interesting little tool. One may find its way into my basement. Thanks for mentioning it.



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post #4 of 9 Old 11-18-2013, 01:28 AM Thread Starter
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A bag of playground sand can last many years if the cat doesn't use the bag. Kitty can make plugging the sandblaster a problem. Wear a dust mask though and some water can tie up and wash the dust away.

A sandblaster is very handy for clearing threads when one cannot get a die onto the area.

One can use walnut shell or other softer materials on aluminum but likely someone with much more knowledge can weigh in. I like that my small home compressor can support a fair number of pulses which is good enough for small jobs.


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Originally Posted by planalp View Post
I checked out that small, portable sandblaster you mentioned, Normk: quite an interesting little tool. One may find its way into my basement. Thanks for mentioning it.
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post #5 of 9 Old 11-18-2013, 08:50 AM
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Quote:
Originally Posted by Normk View Post
A bag of playground sand can last many years if the cat doesn't use the bag. Kitty can make plugging the sandblaster a problem. Wear a dust mask though and some water can tie up and wash the dust away.

A sandblaster is very handy for clearing threads when one cannot get a die onto the area.

One can use walnut shell or other softer materials on aluminum but likely someone with much more knowledge can weigh in. I like that my small home compressor can support a fair number of pulses which is good enough for small jobs.
Hey, that'll work. I've got a compressor that can handle it and I've always got bags of playground sand around I dump in my horseshoe pits from time to time.
Thanks again for the lead.



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post #6 of 9 Old 11-18-2013, 06:09 PM
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Alpheus over on .net uses baking soda or industrial soda, in his Blaster, depending on job.
Can apparently even clean the business end of a KLR Exhaust Valve!

Combustion chamber is apparently "a piece of cake".

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #7 of 9 Old 11-19-2013, 02:03 AM Thread Starter
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Also good for those times when the beer & chilly are too spicy!
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post #8 of 9 Old 11-19-2013, 06:00 AM
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Quote:
Originally Posted by Normk View Post
Also good for those times when the beer & chilly are too spicy!
I can only hope you're not talking about the human equivalent of "cleaning the business end of a KLR exhaust valve."



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post #9 of 9 Old 11-19-2013, 12:28 PM Thread Starter
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There might have been times!

I recommend that your suggested application might best employ low pressure.

Reminds me of a question I think I asked here which received no response:

"During my last annual check-up, the rectal exam was quite uncomfortable. Do you think I should change dentists?"
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