Left light switch assembly Gen 2 on Gen 1? - 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 05-20-2020, 01:42 AM Thread Starter
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Left light switch assembly Gen 2 on Gen 1?

It is a matter of time before I need to replace my left side switch assembly because my turn signal switch has problems. The corner of it is broken away and it is pretty loose. I think it must have taken some kind of hit at some point. Because of the looseness it is almost impossible to reset the turn signal after a left turn without turning on the right signal and having to move it back to center from the right side.

Gen 1 assemblies are super expensive but I have noticed Gen 2 are much cheaper and easier to find. I have a mirror and choke relocation bracket already. with that in mind, would a Gen 2 switch assembly work? If so, would it be plug and play or would I have to trace wires and make a harness for it? Are there other options that are worth looking into without spending a ton of cash? I found a coupe older threads but the links in them were dead and products no longer available. Thanks.
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post #2 of 12 Old 05-20-2020, 02:52 AM
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Electrically it would work, but it would not be plug and play.

You would want to get a connector and crimp tool from Cycle Terminal and replace the Gen 2 connector. I believe that the correct connector would be a Hitachi MTW locking-type.

You could also, of course, simply splice the old Gen 1 connector onto the Gen 2 switch. I would promise not to tell and would rather not look.

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post #3 of 12 Old 05-20-2020, 10:04 AM
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Just an advisory . . . the LATCHING mechanism of the turn signal switch is kinda tricky. If you go in there, then button it up, you'll know a lot more about it than when you began!

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #4 of 12 Old 05-20-2020, 09:57 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Electrically it would work, but it would not be plug and play.

You would want to get a connector and crimp tool from Cycle Terminal and replace the Gen 2 connector. I believe that the correct connector would be a Hitachi MTW locking-type.

You could also, of course, simply splice the old Gen 1 connector onto the Gen 2 switch. I would promise not to tell and would rather not look.
Thank you for the link. When I get to this I will probably just go with the second option and cut the harness off the old switch and splice it. I have a ton of heat shrink tubing and also that corrugated plastic stuff that is split down one side to make it look clean.

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Originally Posted by Damocles View Post
Just an advisory . . . the LATCHING mechanism of the turn signal switch is kinda tricky. If you go in there, then button it up, you'll know a lot more about it than when you began!
When you say the "latching system" are you talking about what holds it on the handle bars?

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post #5 of 12 Old 05-21-2020, 07:33 AM
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Originally Posted by RANGER295 View Post

When you say the "latching system" are you talking about what holds it on the handle bars?
Not at all!

I refer to the mechanism holding the contacts to the turn signal lamps connected when signaling a turn.

Of concern only if you disassemble the turn signal switch; a mechanism latches the switch in the direction signaled (left or right), and maintains the connection 'til the switch lever is returned to its center position. A clever, but tricky, mechanical arrangement in my view. As in, "How do I get these parts back together?"


“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #6 of 12 Old 05-21-2020, 11:20 PM
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I have a old Gen 1 switch that you can have for the price of shipping. I would have to pull it out and check exactly what went on it. Pretty sure it was the hi/low beam switch. Signals worked fine and housing is intact. I’ll have a look tomorrow and get some pictures.

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post #7 of 12 Old 05-22-2020, 12:43 PM
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Pictures attached. Light switch went and I had to put the wires together to bypass it when on a trip.

.
Attached Images
File Type: jpeg D651DCDF-F65A-4872-86CB-DE4D8E6A96AD.jpeg (371.8 KB, 9 views)
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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 12 Old 05-23-2020, 07:06 AM Thread Starter
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Originally Posted by klr4evr View Post
Pictures attached. Light switch went and I had to put the wires together to bypass it when on a trip.

.
Thank you. Two questions...

One, in light of what Damocles said below, do you think I could either use the parts from my assembly to fix the headlight high/low switch on yours or the other way around use the turn parts on yours to rebuild mine? I am pretty handy (a high school shop teacher) but some things just are not made to be taken apart and put back together.

Two, do you have any experience shipping to the US? I am California and I see you are in Canada. I have no idea what shipping would cost.

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post #9 of 12 Old 05-23-2020, 08:25 AM
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Not to discourage international trade, but . . . RANGER295, California is (or used to be) salted with a robust seasoning of motorcycle DISMANTLERS (aka, Junk Yards). Used parts are available there sometimes at cost considerably less than OEM from your friendly local neighborhood Kawasaki dealership (I don't want to destroy support to local dealers, either).


“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #10 of 12 Old 05-23-2020, 09:31 AM
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Quote:
Originally Posted by RANGER295 View Post
Thank you. Two questions...

One, in light of what Damocles said below, do you think I could either use the parts from my assembly to fix the headlight high/low switch on yours or the other way around use the turn parts on yours to rebuild mine? I am pretty handy (a high school shop teacher) but some things just are not made to be taken apart and put back together.

Two, do you have any experience shipping to the US? I am California and I see you are in Canada. I have no idea what shipping would cost.
I would think that it could be made to work with splicing in your headlight switch into this switch. Fewer wires to deal with than the other way around. I will remove the tape from the splice and see what that looks like and take another picture. My brother made the repair on the trail. He’s an electrician so I’m sure it isn’t a mangle job.

As to shipping from Canada it gets stupid sometimes when you send across the border either way. The post office cashed in long ago on cross border trade. It’s worse coming from you to me because of exchange rates. Only way to know with some accuracy is for you to PM me your address and I can plug it into Canada Post shipping calculator. I’m guessing somewhere in the $20 CDN range.

And by all means, as Damocles suggested, check out local breaker yards for the part. Or eBay. It’s not like there’s anything in this for me. Just trying to help.

.

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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