Adding a Fuse Box - 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.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 36 Old 02-13-2013, 05:14 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,443
Garage
Adding a Fuse Box

I decided to go KLR-style with the added fuse box and use an inexpensive fuse panel that is available at Autozone. It's not a Centech or a PC-8, but it gets the job done and for only about $11.

This is all going to get bolted in the California Can spot under the left side panel.

This is the Buss ATC six position fuse panel - 30 amps per circuit, part number BP-15600-06-2; call your local Autozone and see if they stock it. If they don't they can order it and have it in a couple of days.


It needs a mounting plate, which I made in about 30 minutes from a $7 hunk of 22ga sheet metal from Orchard Supply and rattle canned:


I've left room to add the Important Thing I haven't Thought Of Yet

This is the circuitry I'm installing:


The Headlight Kill Panel is down by the battery box and allows me to turn the headlight off and automatically turns it off when the starter is turning. The Stebel horn circuit works with the stock horn in place; I haven't figured out where the Stebel will go. It doesn't want to go under the IMS tank very well.

Here's everything in place and ready for wiring, which I'll do tomorrow. Or the next day. Definitely before next week. Maybe.



T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


Sting like a butterfly.

Last edited by Tom Schmitz; 02-20-2013 at 09:06 PM.
Tom Schmitz is offline  
Sponsored Links
Advertisement
 
post #2 of 36 Old 02-13-2013, 06:49 PM
2nd Gear
 
clogan's Avatar
 
Join Date: Dec 2010
Location: Tennessee
Posts: 322
Cool job!
clogan is offline  
post #3 of 36 Old 02-13-2013, 07:29 PM
1st Gear
 
Join Date: Jun 2012
Location: grayslake IL
Posts: 24
Alarm on a klr!?! What will they come up with next? But seriously, nice job!
K-ris is offline  
 
post #4 of 36 Old 02-13-2013, 08:01 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,215
Cool, Tom, but . . . your wiring diagram shows your headlight-kill relay as NC (normally closed), while the sketch on the relay case shows it as NO (normally open). A relay's NC contacts would be opened by control voltage activation; a relay's NO contacts would be closed by energizing the solenoid.

Or is it just ME?

Have you tested the installation for functionality? If so, I'll hush my mouth, er, keyboard.

And . . . the starter system wiring appears considerably, well, simplified in your wiring diagram, to me.
Damocles is offline  
post #5 of 36 Old 02-13-2013, 10:15 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,443
Garage
Damocles -

The relay on the plate is the horn relay, while the 5 pin relay for the headlight kill is down by the battery box. I have a plate there with the headlight kill switch, the relay, and a PowerLet outlet on it. The relay is on the other side of the plate, held in place by the round head bolt.


And yes, the starter circuit is vastly simplified. It only shows that the starter being active trips the relay and omits the switch, relay and all it's attendant wiring.

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


Sting like a butterfly.

Last edited by Tom Schmitz; 02-13-2013 at 10:21 PM.
Tom Schmitz is offline  
post #6 of 36 Old 02-13-2013, 10:17 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,443
Garage
Quote:
Originally Posted by K-ris View Post
Alarm on a klr!?! What will they come up with next? But seriously, nice job!
It's a small self contained unit and is there not so much for theft protection as it is for "ruh-roh, the bike got bumped, knocked over, or fell over dead".

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


Sting like a butterfly.
Tom Schmitz is offline  
post #7 of 36 Old 02-13-2013, 10:55 PM
Missed Gear
 
Cabrito's Avatar
 
Join Date: Feb 2011
Location: 415&707
Posts: 1,192
Tom,
What about how Snakeboy66 did his stebel horn. http://www.klrforum.com/showpost.php...52&postcount=6 His is a Gen1, but maybe you could make it work on your Gen2

Sent from my rotary phone
================================
Track me here -
https://spotwalla.com/tripViewer.php...354a61e5f3997a
Michael G in SF | 2018 KTM 1090R Adventure | 02 XR400R (Plated) | 2011 FJ Cruiser Army Green |
------------------------------------------------------------
"If you have the will and not the way, you wont get very far."
Snakeboy66
Cabrito is offline  
post #8 of 36 Old 02-13-2013, 11:13 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,443
Garage
I'm pretty sure I could fit the compressor in the back somewhere, possibly under the fuse block plate. I was thinking of putting the horn up behind the engine guard.

It also might fit up under the cowling, as there's a lot of unused space under there.

There's nary a cubic inch of space under that IMS.

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


Sting like a butterfly.
Tom Schmitz is offline  
post #9 of 36 Old 02-14-2013, 12:12 AM
Missed Gear
 
Cabrito's Avatar
 
Join Date: Feb 2011
Location: 415&707
Posts: 1,192
Are you worried about the fuse block catching a lot of dirt and grime mounted back there by the fender?

Sent from my rotary phone
================================
Track me here -
https://spotwalla.com/tripViewer.php...354a61e5f3997a
Michael G in SF | 2018 KTM 1090R Adventure | 02 XR400R (Plated) | 2011 FJ Cruiser Army Green |
------------------------------------------------------------
"If you have the will and not the way, you wont get very far."
Snakeboy66
Cabrito is offline  
post #10 of 36 Old 02-14-2013, 12:46 AM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,327
I like your Headlight Kill circuit. Perhaps I'm overly sensitive, but the "always on" headlight requirements for motorcycles has pissed me off for years, along with kill switches under lawnmower seats and those dumbass chainsaw "clutches" you have to squeeze against the top bar to start and use them. Ralph Nader, I curse you to this day.....



planalp is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Adding Upgades to my 09 KLR. orphanmonkey 2008+ KLR650 Wrenching & Mod Questions 5 06-01-2012 03:34 PM
Adding A Light planalp 2008+ KLR650 Wrenching & Mod Questions 15 09-14-2011 08:15 AM
Adding Oil Almost Every Ride..Normal??? ridgerunner 1987 to 2007 Wrenching & Mods 6 01-16-2010 08:51 PM
Adding a Cell Phone Holder klr650 How To's & Tech Guides 2 06-25-2009 02:14 PM
What fuse should i run ? Bratski 1987 to 2007 Wrenching & Mods 7 03-03-2009 02:45 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome