Wiring harness connections & locations - 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 45 Old 08-10-2014, 02:58 PM Thread Starter
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Wiring harness connections & locations

I ordered a wiring harness off EBay with the intention to identify the locations for all terminations, the specific routing of all wires. This is intended to add to the wiring plug pin outs which I attempted to describe a while ago.

The intention is to describe where each wire is actually routed and where connections are actually located on the bike. I thought this might be useful to some people as the wiring diagram doesn't show where wires actually branch from one another. The harness is in Deming, Wa until either Mike or I visit but hope to have it in the next week or so.

The purpose of this post is to ask whether you might consider what information might be useful in this regards and how best to present. My basic plan is to lay out the harness roughly onto my bike to describe/photo the harness location, then strip the loom and trace each wire.

Thoughts, suggestions, additions?

I don't personally require this information so this is only a KLR-public service initiative.

I have the main harness only since the tail and front sub-harnesses would be an additional expense. I might buy them in future to complete this or someone else may have a donor or sacrificial sub-harness to use.
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post #2 of 45 Old 08-29-2014, 12:42 PM Thread Starter
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The harness arrived and since my bike is tied up waiting for a new exhaust gasket to replace the one robbed to get a traveller going, might be a good time to do the harness location.

I didn't hear any responses with regards thoughts and suggestions so thought I'd ask again because it's hard to go back once something it pulled apart.
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post #3 of 45 Old 08-29-2014, 02:25 PM
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Quote:
Originally Posted by Normk View Post
The harness arrived and since my bike is tied up waiting for a new exhaust gasket to replace the one robbed to get a traveller going, might be a good time to do the harness location.

I didn't hear any responses with regards thoughts and suggestions so thought I'd ask again because it's hard to go back once something it pulled apart.
I'd find it beneficial. thing is a damn mystery to me.

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post #4 of 45 Old 08-29-2014, 02:38 PM
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Could you reverse-engineer it onto a wiring loom pin board with labels?



I have a Gen2 harness. I could follow your lead on the front and rear sections.

Tom

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post #5 of 45 Old 08-29-2014, 08:02 PM
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Quote:
Originally Posted by Normk View Post
The harness arrived and since my bike is tied up waiting for a new exhaust gasket to replace the one robbed to get a traveller going, might be a good time to do the harness location.

I didn't hear any responses with regards thoughts and suggestions so thought I'd ask again because it's hard to go back once something it pulled apart.
It seems to me that a photo of the harness laid out on the bike with each subsystem connector labeled or numbered with a table showing the subsystem associated with each number would do the trick. The wiring diagrams show the wire colors and the connectors they run between. Knowing where the connectors are and the wire colors should allow the user to trace any wire/s he is interested in between connectors.

No use to destroy a good harness and I think it would be difficult to follow the wires on a small scale photo anyway.

I picture something like this with the connectors labeled. http://www.kawasakipartsnation.com/o...ical-equipment
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post #6 of 45 Old 08-30-2014, 12:15 AM Thread Starter
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I don't have room to store a pin board so will have to do a one-time then likely just dump the harness into the box of wiring. Good idea though, on the same line as Gomotor's I think. I will go along those lines.

I'm not planning to retain the harness or to re-loom it because I would use an old harness to rewire a bike. I'd simply build a new one using better strategy than was used. The KLR needs a better ground system, headlight relays or HID, a main power distribution relay up front, horn relay, better fan wiring, etc. Simpler to do it right than to use an old harness and then modify, IMO. Keeping in mind I'm old and cranky. ;-)





Quote:
Originally Posted by Tom Schmitz View Post
Could you reverse-engineer it onto a wiring loom pin board with labels?



I have a Gen2 harness. I could follow your lead on the front and rear sections.

Tom
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post #7 of 45 Old 08-30-2014, 09:38 AM
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Yes, I was thinking a quick-and-dirty pin board just to show the stuff before you align it along the bike would be helpful. No need to keep it; you're not running a museum!

I have added so much to my wiring that I have thought about taking the harness off and re-building it. Note, thought about it.

Tom

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“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #8 of 45 Old 08-30-2014, 09:42 AM
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Quote:
Originally Posted by Tom Schmitz View Post
Yes, I was thinking a quick-and-dirty pin board just to show the stuff before you align it along the bike would be helpful. No need to keep it; you're not running a museum!

I have added so much to my wiring that I have thought about taking the harness off and re-building it. Note, thought about it.

Tom
Ugh, that doesn't sound the least bit fun.

2005 KLR 650- Red & Black
Wheeeeee!!!
Blog
Farkle:
Skid Plate, Crash bars, Happy Trails fork brace, rear rack and aluminum cargo boxes, Africa switch, heated hand grips, rear master cylinder guard, taller wind screen, UNI air filter, SuperTrapp exhaust, HD shifter, off road pegs, HWY pegs, .22’ mod, 12.9 sub frame bolt upgrade, shortened clutch and hand brake levers, MSR handle bar bash bars, headlight guard, center stand, LED tail light and driving lights
...
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post #9 of 45 Old 08-30-2014, 01:40 PM Thread Starter
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When you said that I'm not running a museum, it forces me to conclude that you haven't seen my sock drawer.

Your comment regarding additions to the harness makes me think that a thread to discuss what might be the ideal harness design and/or what are the best additions/modifications to the harness. When one sees nearly 2 volts drop in the headlight circuit, over a volt to the cooling fan and so on, it makes me think that there are so many owners out there who might undertake some improvements if these were explained and described.

I have a front brake modification on the go, planning to play with a different MOSFET VRR and this harness in addition to ongoing stuff with friends's bikes so might be a while but please consider whether you would be willing to help start such a thread. I know there are others here which are more than capable of adding ideas and catching problems.




Quote:
Originally Posted by Tom Schmitz View Post
Yes, I was thinking a quick-and-dirty pin board just to show the stuff before you align it along the bike would be helpful. No need to keep it; you're not running a museum!

I have added so much to my wiring that I have thought about taking the harness off and re-building it. Note, thought about it.

Tom
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post #10 of 45 Old 08-30-2014, 02:03 PM
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Watch this forum trickery....

Tom [email protected]

“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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