KLR650 2006 rewiring - 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 7 Old 12-19-2015, 07:50 PM Thread Starter
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KLR650 2006 rewiring

Hi all, first time poster here wanting to know if I can get some advise here on a KLR650 that has been heavily modified. I didn't inspect the bike real well when I bought it and 2.5 months later, when the bike seat started smoking I discovered the mess that the bike's electricals were in.

I need to rebuild the wiring from scratch. I have a lot of questions and will have more when I progress through this project, such as, which circuits should have relays and fuses, etc. What are the specs of the wires used (white, brown, yellow, etc).

I've added some pictures so you can see what I'm starting off with, thanks all for your direction.











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post #2 of 7 Old 12-20-2015, 03:04 PM
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Nice bike. What tank is that?
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post #3 of 7 Old 12-20-2015, 04:44 PM
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Were it mine I'd buy a stock harness from e-bay and start over rather than try to fix what's there. You've shown a lot of burned areas where the magic smoke has gotten out. There could be damage you won't see until you start to peel back the wrapping.

Check on the ignition system to determine whether you should start with a Gen 1 or with a Gen 2 harness. That thing looks to be at least half Gen 2; make sure that the electricals were grafted over, too, or that it is not some sort of 2006-VIN-on-a-Gen 2 sorta deal.

I am presuming that you are in Australia, so I've no idea if you have a ready source of used harnesses.

Tom

p.s. What's the bike behind the KLR?

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Last edited by Tom Schmitz; 12-20-2015 at 04:54 PM.
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post #4 of 7 Old 12-20-2015, 07:06 PM Thread Starter
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Originally Posted by Tom Schmitz View Post
Were it mine I'd buy a stock harness from e-bay and start over rather than try to fix what's there. You've shown a lot of burned areas where the magic smoke has gotten out. There could be damage you won't see until you start to peel back the wrapping.

Check on the ignition system to determine whether you should start with a Gen 1 or with a Gen 2 harness. That thing looks to be at least half Gen 2; make sure that the electricals were grafted over, too, or that it is not some sort of 2006-VIN-on-a-Gen 2 sorta deal.

I am presuming that you are in Australia, so I've no idea if you have a ready source of used harnesses.

Tom

p.s. What's the bike behind the KLR?

The bike behind is my wife's Suzuki TU250X or the Tux.

I'm actually thinking of not going for the standard harness because I don't have a standard dash. I have a Vapour dash: (Sorry can't link)

So since posting this someone has pointed me to the Motogadget M-Unit and M-Button: (Sorry can't link)
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post #5 of 7 Old 12-20-2015, 07:29 PM
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A reasonable course of action.

I might suggest that you try and buy a car harness to get yourself a cheap stock of wires of various colors, stripings, and gauges to make life a bit easier.

The KLR harness is too botched up from the factory to rework into a simple harness. It is full of splices and short bits of wire.

Go ahead and post the links, but bodge them up with a space between the www and the rest of it; I'll fix it so we can see it.

Like this: w w w . kawasakipartsnation.com/oemparts/a/kaw/500b57def8700223e4796b09/crankcase

Tom
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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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post #6 of 7 Old 12-20-2015, 08:24 PM Thread Starter
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Nice bike. What tank is that?
It came from a Honda XL 500
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post #7 of 7 Old 12-21-2015, 08:31 AM
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It came from a Honda XL 500
Looks good on the KLR. Any mods needed to get it mounted?
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