Power Source For Aux Lights - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 19 Old 05-26-2011, 01:22 AM Thread Starter
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Power Source For Aux Lights

Wondering if anybody could help me with this.

I'm planning on putting a pair of cheap 55w Walmart lights on my KLR to improve my lighting and as a backup for my headlight circuit in case it fails.

I don't want to tie this circuit to my hi/low beam switch as where I'm riding, I won't have a need to quickly shut them off for approaching vehicles.

But, I also don't want the aux lights power circuit to be totally dependent on a switch; i.e., if it's daylight and somehow the switch gets turned on and the lights come on and I don't notice, I don't want them to drain my battery.

How should I power these lights? I was planning on just wiring them directly to the battery, but it doesn't seem like a good idea. Any way I can do this to where if the ignition switch is off, the lights can't come on? My comprehension of circuits and electricity in general is pretty limited.



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post #2 of 19 Old 05-26-2011, 03:00 AM
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Is your KLR pre '08? If so here is how I would do it....

Parts needed besides the lights themselves-
Switch
Fuse holder with 10 amp fuse.
SPST Bosch style relay. This is the typical 4 prong relay available everywhere.
Wire and connectors.

Run a red 12 gauge wire directly from the battery to the front of the bike. On the end going to the battery add the fuse holder. This will connect to the positive side once everything is wired up.

The other end would come out somewhere behind the front fairing. I would mount the relay somewhere in there. This end would connect to pin 30 on the relay.
From pin 87 run the 12V+ power to the lights your installing.

Now to provide switching the lights on and off. If you look in the KLR's fairing there are those two wires that are un-used. One is brown with a white stripe and the other is black with a yellow stripe. These are used on the european bikes but not used on US bikes. The brown/white wire is 12V+ when the key is on and the black/ yellow is the ground.
Run a wire (16 gauge) from the brown/white stripe to wherever you mount the switch. then run a wire from the other pole on the switch to pin 85 on the relay.
Connect the black/ yellow stripe wire to pin 86 of the relay.

From your Aux lights you can either run the negative back to the battery or ground it to the frame.

So now what you have is AUX lighting that only works with the key on and the switch in the on position.

So what you have at the relay is...
Pin 85 12v+ swtiched power. this activates the relay when the key and switch is on.
Pin 86 Ground for the relay.
Pin 30 12v+ from battery.
Pin 87 12V+ comes out of here to lights.

-Tom.
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post #3 of 19 Old 05-26-2011, 03:09 AM
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Here is a link that shows how the relay works and how it's wired.
http://www.eurekaboy.com/f250/relay101.htm

'89 KLR685, 05' 1200 Bandit.
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post #4 of 19 Old 05-26-2011, 04:55 AM
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T748's plan appears sound.

The unused wires he suggests as control voltage for the relay are called the "City Lights" conductors on KLR wiring diagrams.

I would "second" T748's recommendation to use a chassis ground or separate wire to the battery negative terminal to ground the lights, rather than exploit the ground wire of the City Lights circuit for this purpose, because--the City Lights wire may not be adequate for carrying the return from two 55-watt auxiliary bulbs; the conductor was only intended for low-amperage "marker" lights.

A good chassis ground would be located near the lights to minimize wire voltage drop.

The City Lights wires will be fully adequate to activate the relay, but questionable to carry the full current of two 55-watt auxiliary light bulbs, IMHO.

A chassis ground should involve bare-metal contact, free from paint or corrosion; or--use instead an adequately-sized wire direct to the battery negative terminal.

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

For '08 and later KLR's, you may use a splice to a BROWN wire as + 12 volts to activate the relay (BROWN is active when the ignition switch is ON). For a ground to activate the relay, a BLACK/YELLOW wire splice or chassis ground will work (o.k. for controlling the relay, but . . . the lights should have a separate and more robust ground for full current, IMHO).
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post #5 of 19 Old 05-26-2011, 05:15 AM
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Back to the drawing board. The OP rides an '09 Gen II.

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post #6 of 19 Old 05-26-2011, 05:59 AM
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Oh well, it should still work, it's just a case of finding a "key on" power wire to tap into. Maybe one of the 2nd gen folks can help. -Tom.

'89 KLR685, 05' 1200 Bandit.
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post #7 of 19 Old 05-26-2011, 06:17 AM
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Quote:
Originally Posted by vatrader View Post
Back to the drawing board. The OP rides an '09 Gen II.
Perhaps you overlooked this element of my post above, vatrader:

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

For '08 and later KLR's, you may use a splice to a BROWN wire as + 12 volts to activate the relay (BROWN is active when the ignition switch is ON). For a ground to activate the relay, a BLACK/YELLOW wire splice or chassis ground will work (o.k. for controlling the relay, but . . . the lights should have a separate and more robust ground for full current, IMHO).

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

The only difference between the two generations in wiring this modification is: Source of control voltage for the relay.

Generation I: City Lights

Generation II: BROWN wire splice and BLACK/YELLOW splice (or chassis ground, in the latter case).

Otherwise, everything else in T748's writeup remains valid, for either generation.

============================

By the way, vatrader; please read your PM'S!

Thanks.
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post #8 of 19 Old 05-26-2011, 06:27 AM
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No perhaps about it....I missed the additional information.

Just didn't want to see a bunch of poor Gen II riders spending the day snooping around under the fairing, looking for something that isn't there....

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[/I]
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post #9 of 19 Old 05-26-2011, 06:33 AM
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Originally Posted by vatrader View Post
No perhaps about it....I missed the additional information.
Good!

Now, what about the PM's?
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post #10 of 19 Old 05-26-2011, 07:08 AM
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Quote:
Originally Posted by Damocles View Post
Good!

Now, what about the PM's?
Check your PM's.

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[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

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