denalli lights - Kawasaki KLR 650 Forum
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post #1 of 10 Old 04-07-2013, 05:47 PM Thread Starter
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denalli lights

Just added a set of denalli micro driving lights,directions were pretty simple. I tapped the switch wire into the dash lights which are key operated and the other positive and negative to battery. They work great except after bike sat for four days the battery was dead. I realized that when the leads are hooked to battery ,the relay is energized and stays energized after bike is turned off,thus draining the battery. What up? Stumped.
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post #2 of 10 Old 04-07-2013, 06:03 PM
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post #3 of 10 Old 04-07-2013, 07:05 PM
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Quote:
Originally Posted by donavon View Post
Just added a set of denalli micro driving lights,directions were pretty simple. I tapped the switch wire into the dash lights which are key operated and the other positive and negative to battery. They work great except after bike sat for four days the battery was dead. I realized that when the leads are hooked to battery ,the relay is energized and stays energized after bike is turned off,thus draining the battery. What up? Stumped.
I take it the lights are not on when the bike is turned off? I see the Denali wiring diagram on their site and it looks pretty fool proof. If the relay is activated and wired as per the diagram, then the lights will be on and if your switch wire to the relay is not powered when the bike is off then suspect a bad relay.

Can you hear/feel the realy switch as you turn on/off the bike power? Have you checked your switch wire to the dash lights to be sure that source is actually off when you turn off the ignition?

Ron
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post #4 of 10 Old 04-07-2013, 07:34 PM
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check for voltage when the bike is off,could be something else wired into the circuit?
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post #5 of 10 Old 04-07-2013, 08:00 PM
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The relay most likely only 4 leads to it, correct?
Should be (I'll use numbers from a standard Bosch style relay - the numbers may be on your relay as well, they are standards):
  • 30 - Constant power in (could be key-switched power unless you want the lights to be able to be on with the bike off). This is the main power that'll feed to the lights, so you do need to have some concern with the current draw on this circuit, if you are tapping a fused circuit.
  • 86 - Switched power in. Probably a switch that came with the lights, or you could tap voltage at the wire going into the headlight if you want them on all the time without an independent switch.
  • 85 - Ground. This is just for the magnetic switch inside the relay, but it doesn't work if you aren't grounded.
  • 87 - Supply power out. This powers your lights.

If it has five terminals (standard Bosch style relay), then there's an additional terminal that becomes engaged when power is removed from the circuit - labeled 87a. You do NOT want to use this one.
From your complaint - my first guess would be that you are using that one.

In that event, when you turn the switch in the direction that supplies energy to the relay, the lights would turn off, rather than on - and with the switch in the position that you are thinking is "off", you're creating a drain on the battery.

If you use terminal 87 on the relay, then when the switch is truly "off", power is cut to the relay, the connectivity to terminal 87 is terminated (87a becomes engaged simply because that's it's fall-back position), and the lights will go off.

My guess is that possibly they gave you a real 5-terminal relay, with instructions to not use one of the terminals, and you are simply plugged into the wrong one, from your symptoms. 87, not 87a.

Let me know if I'm right.
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post #6 of 10 Old 04-07-2013, 09:20 PM Thread Starter
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Switched wire is correct,light inside switch only comes on when key is turned on. As I said the lights turn on and off with switch if the ignition is on . Can only hear relay click once its connected to battery. Will check out relay a little closer tomorrow as to if it's a 4 or 5 post. I too thought the wiring was fool proof,---wrong.
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post #7 of 10 Old 04-07-2013, 09:51 PM
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Is this the diagram?: webbikeworld.com/lights/denali-dm1-micro/denali-dm1-light-wiring-diagram.jpg

It looks like the plug for the relay is pre-wired.
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post #8 of 10 Old 04-07-2013, 10:23 PM
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Quote:
Originally Posted by wansfel View Post
Is this the diagram?: webbikeworld.com/lights/denali-dm1-micro/denali-dm1-light-wiring-diagram.jpg

It looks like the plug for the relay is pre-wired.
Interesting.
Based on the symptoms, I'm still suspecting that is the case.
If it's a 4-terminal relay, then that's out, not the problem, possibly just a defective switch or the like (unplugging the switch and seeing if the drain goes away would help diagnose that).
But if it's a 5-terminal relay, then it's possible that the pre-wired socket is wired incorrectly, effectively resulting in what I described. It would make sense.

This company may actually use a high quality relay - if so, it likely has the numbers I mentioned stamped on it by the terminals, so you can check yourself.
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post #9 of 10 Old 04-08-2013, 12:06 PM Thread Starter
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Goelemon,you'll have to send me a repair bill. You were dead on. It was a 5 post relay with 87a not being used. The plug from factory was incorrect. They had the constant hot on the (85) ground terminal,theground was on the switched power(86) terminal, all jacked up. Pulled all connectors out of plug and did it as you said,the numbers were identical. Now the relay energizes only when lights are turned on. Perfect.
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post #10 of 10 Old 04-08-2013, 04:39 PM
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Beautiful! Good to hear.
I take KLR 650's as tips... not sure what you'll ride if you send me yours though, so I guess you probably should keep it...
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