Lights in the cluster - 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 12 Old 06-18-2014, 08:47 AM Thread Starter
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Lights in the cluster

Hey all... I've been on the bike for about a week now and a couple days ago I rode at night for the first time. Half of the cluster is dark (tach side). I'm assuming that's not normal but thought I'd ask here before opening it. Thanks
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post #2 of 12 Old 06-18-2014, 10:15 AM
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Quote:
Originally Posted by mungo View Post
Hey all... I've been on the bike for about a week now and a couple days ago I rode at night for the first time. Half of the cluster is dark (tach side). I'm assuming that's not normal but thought I'd ask here before opening it. Thanks
There are small bulbs behind the instrument panel that keep it lit. Take of the four screws for the windshield and you should see them on the back of the instrument panel. Just pull and see if they are blown.
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post #3 of 12 Old 06-18-2014, 11:01 PM
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Mungo, I see you send I share the same attitude towards our bikes.
I like to see the help from Fradsham and the like. This is why I like this site, and especially, the members who help others.
Jack
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post #4 of 12 Old 06-18-2014, 11:33 PM
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An alternative: I find it easier to leave the windscreen in place and to remove the speedo cable nut from the speedometer. Remove the two large Phillips head screws (one from each side) to release the black plastic cover over the wiring plugs below the instrument cluster.

There are two 5 mm nuts and washers (8 mm wrench) holding the instrument cluster to the mount's rubber grommets. One can locate them quite easily by wobbling the instrument cluster as they will be seen to pivot.

Place a rag or pad to one side (I prefer the left as am right handed) lift the instrument cluster up, invert and place onto the pad. The instrument illumination lights are under the small "rubber" plugs. The speedo has (2) and tach (1). They use #194 bulbs which are common "peanut base" bulbs from any auto parts store.

FWIW, I've installed quite a few of these EBay LED bulbs and prefer the light level. They will do the high beam also but the neutral is a tiny bulb (can't recall the number) One cannot directly install an LED for the turn signal indicator. http://www.ebay.com/itm/1-10-x-T10-5...item5d4a7c0e42

HIH
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post #5 of 12 Old 06-19-2014, 07:35 AM
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sorry mungo about my advice, I did not realize it was the 1997-2007 version, when I clicked the new posts link. The 2008 has a different instrument panel than the 2007, and my instructions was for the new panel.

i would listen to NormK on this one.
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post #6 of 12 Old 06-19-2014, 09:19 AM Thread Starter
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Jack- Ya, this place is awesome!

Normk- Wow and Thanks! Are the LEDs brighter? or a different colour?

fradsham- No problem and thanks anyway. You guys all seem to go the extra mile.... I'm really glad I joined the site
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post #7 of 12 Old 06-19-2014, 12:40 PM
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fradsham: I was chuckling when I read your post because I must have looked back and forth 5 times trying to make certain that the bike was Gen1. Even when I posted, your instruction made me think that I had it wrong.

The LEDs seem brighter to me and are white which seems to be a better bet than the yellow, sometimes sort of white, from the stock bulbs.

I'm going to go on a bit here so if someone doesn't like that, please just ignore my posts. I'm trying to provide more complete information in case it is useful to someone.

As you are likely aware, motorcycles tend to use very marginal wiring (too small wire) so there is always excessive power loss in the circuits. The dash lights come off the "Brown Wire" along with almost all the other loads on the bike so the voltage to the dash lights is often 2 volts or more lower than the battery/alternator voltage. When one is riding with around 14-1/2 volts at the battery, the dash lights may only be "seeing" around 12 volts so they are dimmer than intended. If one installs LEDs, the load on the wiring is less so the voltage will come up a tiny amount.

This means that one wins in two ways, higher voltage to the LEDs and also that the LEDs will make brighter light at the lower voltage than do the dash lights. If one rewires to put alternator/battery voltage to the dash lights, then they are decently bright...close to the LEDs.

I can't post any more photos here because have reached the limit so can't help by posting photos of the dash removal or locations of the items. If you would like to PM me your email, I'll send photos and can describe further if you wish help. While you're in there, think about recalibrating your speedometer. All you need is a GPS or known good speed to compare with the displayed speed on your speedo. They usually read 6 - 10 mph high.

I've asked the contact us twice as to what is possible regarding posting more photos but so far no response. I'm looking for another web group which takes photos and bans rudeness and name calling. Any suggestions?

I like this group but find it constraining not be be able to offer more detail.




Quote:
Originally Posted by mungo View Post
Jack- Ya, this place is awesome!

Normk- Wow and Thanks! Are the LEDs brighter? or a different colour?

fradsham- No problem and thanks anyway. You guys all seem to go the extra mile.... I'm really glad I joined the site
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post #8 of 12 Old 06-22-2014, 08:18 AM Thread Starter
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Hey Normk, thanks for the instructions. Lots of good info there ..and lots that I didn't know! That was a huge help.

Don't have any suggestions for other sites though. This is the only klr one that I've joined. I'm a member of the toronto and area bike forum but very rarely post there.
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post #9 of 12 Old 06-22-2014, 12:30 PM
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Some very helpful guidance has me on the road to uploading to Photo Bucket and will try that approach. It's the one step more problem always...

While you're in there, think about adding a 4-Way flasher function. It's easy to do, just replace the stock signal flasher with a Tridon HD12 or one of the 3-terminal electronic ones off EBay. Then all you need to do is make a small wiring harness using an on/off switch. The two terminals from the switch, each have a wire leading down to the signal light bullet connectors where the signal light mounting tubes come into the fairing. Either tap into the "hot" side of each light circuit or make a "Y" adapter with male & female terminals.

With male & female, one just unplugs the hot wire male from female and plugs the two into the harness. All the switch does is to connect the two signal wiring together side to side. Flip the 4-Way switch to On and signal either direction and all 4 will flash.

I use this function frequently when pulled over, or when going through construction zones.

Soon as get the photos handled will post a better description.

HIH

Norm



Quote:
Originally Posted by mungo View Post
Hey Normk, thanks for the instructions. Lots of good info there ..and lots that I didn't know! That was a huge help.

Don't have any suggestions for other sites though. This is the only klr one that I've joined. I'm a member of the toronto and area bike forum but very rarely post there.
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post #10 of 12 Old 06-24-2014, 08:19 AM Thread Starter
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Hey Normk, that four-way flasher idea is great! I look forward to the pictures.
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