Wiring Loom Pin-Out or Diagram? - 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 53 Old 09-15-2017, 09:58 PM Thread Starter
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Wiring Loom Pin-Out or Diagram?

Hey Everyone,
I just picked up a 1993 KLR today with only 4500mi on it, but it's sat for a long time. I know I gotta go through and replace the cables (rusted and super stiff) and change ALL of the fluids (Did that as soon as I got the bike home).

However
The wiring was a bit of a mess on the bike. Half the wires were either worn through, spliced poorly, or not connected to anything.
I attempted the re-wire the bike to what I thought would be right, but I presume it's not.

I have operating low/high beams and a working cluster, but that's it. It will not turn over or even click a solenoid to attempt to start and there are no blinkers or tail lights.

Is there something I should look for specifically or should I try and pick up another wiring harness from a wrecked KLR?
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post #2 of 53 Old 09-16-2017, 11:53 AM
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Might just want to replace the entire Wiring Harness and use what's left of the original for spare parts/connectors etc.

I found the following Part Numbers and Prices from an on-line dealer. If you Google the Part Numbers and/or eBay they might even be found for less.

26030-1008 HARNESS,MAIN $155.64
26001-1822 HARNESS,RR $25.69
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post #3 of 53 Old 09-16-2017, 12:23 PM Thread Starter
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Quote:
Originally Posted by Bluehighways View Post
Might just want to replace the entire Wiring Harness and use what's left of the original for spare parts/connectors etc.

I found the following Part Numbers and Prices from an on-line dealer. If you Google the Part Numbers and/or eBay they might even be found for less.

26030-1008 HARNESS,MAIN $155.64
26001-1822 HARNESS,RR $25.69
I PM'ed you with my email, but I might have to go that route. I was hoping to have the bike running by this Sunday.

DO NOT QUESTION IT!
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post #4 of 53 Old 09-17-2017, 02:13 AM
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Once was an inmate (don't recall the username entirely, ended with "K," if memory serves) on this website who posted (on DROPBOX) all you ever wanted to know but were afraid to ask about KLR wiring harnesses.

Links to this wiring data archive may still be up on the existing posts.

Maybe some knowledgeable inmate can steer you to this repository of information.

----------------------

EDIT: Just remembered; the inmate in question was, "NormK."

Last edited by Damocles; 09-17-2017 at 02:17 AM.
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post #5 of 53 Old 09-19-2017, 11:24 AM Thread Starter
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New Harness

Hey Guys,

Thanks for the replies. I ended up just buying a harness off a 1999. Same part number and in a hell of a lot better shape than my harness.
I'll post pictures of the harnesses next to each other once I get the harness on Thursday. Perhaps once I have the old harness out, I'll fix it and hold onto it. I already re-pinned the taillight harness, so that's good to go.

I'm hoping to have this bike up and running by Friday, or at the latest Friday night. It's supposed to be a beautiful weekend here in Northeastern PA.

Let's clock up some miles on my 4500mi "Hoopty!"
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post #6 of 53 Old 09-21-2017, 06:02 PM Thread Starter
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So I replaced the wiring harness and I have power, but I have nothing.
As far as I know everything is plugged in correctly, but I don't even have lights now. Whenever I try to operate something on the handle bars, the temperature gauge goes crazy, but that's all that happens.
I think this bike seriously hates me already.

The only thing I noticed, which I had on the last bike was a black and yellow wire that has an eyelet for a ground it looks like and then I have one on the positive battery side with a pin connection. Where would these go? Those are the only two wires I'm really scratching my head on, besides what ever the hell is going on with it having no lights, no start, but it has power everywhere.
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post #7 of 53 Old 09-21-2017, 06:50 PM
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I've got this but the DropBox links no longer work.

http://www.klrforum.com/1987-2007-wr...rness-key.html

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #8 of 53 Old 09-21-2017, 07:22 PM Thread Starter
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Everything is where it's supposed to be. Now something has to be drawing power, but what, I have no idea. Unfortunately my multimeter leads decided to take a shit, so I'm at a loss for what's shorting.

I'm half tempted to just merge the old harness and this one since the old one at least had the headlight working. This new harness only lets the neutral light work and sends the temperature gauge into a frenzy if any of the handlebar controls are used. Now I did notice if I ground the ground to battery (black/yellow by the rectifier with the ball end) wire to the frame and the common ground (black/yellow eyelet by the CDI box) on the frame I will get the blinkers to work, but the relay sounds pretty pissed off when they do work.

I know that's not very much help, but electrical is my weakest link for my mechanical knowledge.
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post #9 of 53 Old 09-21-2017, 10:30 PM
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Black and yellow is the main ground buss. If you have a B/Y wire with an eyelet it should probably go to a frame ground.

What color is the wire coming off the positive battery connection? There should only be a heavy cable going to the starter relay and a white wire. The white wire runs everything electrical except the starter motor. It should be connected to the main fuse.

If you don't have a wiring diagram, look here: http://www.klrforum.com/1987-2007-wr...t-gen-1-a.html

Tom [email protected]

I lit a cigarette and dragged a smoking stand beside the chair. The minutes went by on tiptoe, with their fingers to their lips. -Philip Marlowe

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


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post #10 of 53 Old 09-22-2017, 12:41 AM
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See if the attached helps at all:

As Tom point out the Black wire with the Yellow Tracer (Bk/Y) is Chassis Ground. I suspect that the "eyelet" that you refer to should be attached where the Bracket that holds all of the Relays, the CDI Unit, the Horn and Coolant Overflow Bottle (among other things) is bolted to the Frame. If you remove the uppermost bolt (it's not a big one), there is (or should be) a Bk/Y wire (Ground), with an eyelet that is sandwiched between this bracket and the frame of the motorcycle.

Last edited by Bluehighways; 08-31-2018 at 01:20 AM.
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