Wiring harness connections & locations - 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 9 Old 09-28-2014, 05:54 PM Thread Starter
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Wiring harness connections & locations

The Gen1 wiring project is nearing completion and having been asked about Gen2, I'm wondering if someone might help out with some photos of a Gen2 harness off the bike?

Location photos showing any and all of the wiring plugs locations on the bike would also be helpful. I will have to wait until a Gen2 bike is here with some time to spend but will gather more information at that time.

It's coming into not-riding time for some folks so hoping we can obtain some of the photos.

Anyone able to help?

No electrical knowledge is necessary, just willingness to look and take some photos.
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post #2 of 9 Old 09-29-2014, 04:05 AM
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I may be able to take some pictures, but probably not for another 3-5 weeks. Life is just too crazy right now to take on another project. But i would like to see the info available for gen2's like you did for gen1's.
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post #3 of 9 Old 10-01-2014, 02:11 PM Thread Starter
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Not a hurry as can't move forward until someone can help. Please keep it on your list. I find it to be very difficult to obtain help for these kinds of efforts which surprises because it should be an opportunity for the less technical to pay back/pay forward. Perhaps some are concerned that they may not understand what is needed or may receive criticism?

Simply wondering as finding a way to bring more people into some of these simple efforts would seem to benefit everyone needing the information but it appears that the presentation/request is poorly framed when I offer it.
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post #4 of 9 Old 10-01-2014, 03:10 PM
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I will be tearing into my bike in a month or two to check valve clearance, so i can take a bunch of pictures then. I think people see something about wiring harness and automatically think "i don't know anything about that, i can't help." Probably without even reading what it is you want help with. If you could give me a list, or something, of what exactly you want, i will do my best to get it all.
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post #5 of 9 Old 10-01-2014, 04:43 PM Thread Starter
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I hope that I didn't appear to be critical or petulant regarding encouraging help as that is not my focus. I'm simply trying to work out how I might phrase such a message more effectively.

Not a hurry from my side to get the information as it's not going anywhere without someone's help, or until a Gen2 comes with time to spend. Unfortunately, most times the bike is under pressure to continue the trip or get home so time not available to probe and photo.

My concept is to have a photo of the complete wiring harness, off the bike, and laid out so that the relationship of all the plugs and branches of the harness can be seen at one view. Each can be named and numbered to help to identify in other views. This will require the help of someone who is or has replaced a Gen2 wiring harness. I doubt that your level or altruism will be sufficient for you to remove and reinstall your main harness? ;-)

Another set of views will be the individual locations of the wiring plugs and connections. These will show the names and numbers as in the previous view for identification and cross reference. Obviously it will require a number of photos to cover all the connections in a way in which they can be seen. This will also aid in locating components such as signal flasher, diodes, etc. I know that telling someone to check the diodes, for example, isn't much help if one doesn't know what they look like or where are located. Trying to help that also.

Another is to show sketches of each wiring plug as Tom most kindly created for the Gen1 project. This is made much easier if someone could sketch each plug to that is can be identified and possibly a "Tom quality" drawing made. This also needs to have the wires numbered and a legend made showing that that "Pin 1 is Black/Yellow", for example. One needs to indicate the view so that one knows whether one is looking at the back or front of the plug. In some cases the wires leading from the male plug are different than those from the female so we need to identify that.

Following that, I blanked out all but the plugs on a wiring diagram and labelled/numbered the plugs so that they are more easily found either on or from the wiring diagram.

With that information in hand, one can do a circuit description which indicates which wires connect from one plug to another(s).

Then cross referencing and double checking until one begins to jibber... ;-)

As for not knowing, my premise is that KLR owners are bright people, generally, and the help of someone who has little to no electrical experience would actually be most helpful. Since I don't need most of this information for my own work, the intention was to create some instruments which will help those with less electrical experience. Problem with developing any educational instrument is that we tend to see what we expect and to conclude what we already have concluded. So often these things are next to useless or even more confusing (as in "assemble your new furniture" instructions) so I'd really appreciate someone's help in walking through any or all of this.

It would be better by PM/direct email and any part of it would be most appreciated.

If you don't do electrical but are willing to do some looking and discussing, please send a PM so we can improve this. The old guard who have done a lot of electrical won't be much help as we are not the intended target group.

Anyone? Please.....
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post #6 of 9 Old 10-09-2014, 04:17 AM
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I have a Gen 2 harness in the Shed of Horrors. I'll get started on it in a week or so.


Tom [email protected]

ďThe kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother.Ē -Philip Marlowe

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

Sting like a butterfly.
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post #7 of 9 Old 10-09-2014, 08:03 PM
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When i click on the links, i just get an errror that the link is not found. But then again, my computer has been acting up lately.
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post #8 of 9 Old 10-10-2014, 01:47 PM Thread Starter
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I will repost links as they may have malfunctioned, sorry.

I think that the strategy I employed in the linked pages is not effective so plan to try another. I had intended to show the junctions and to describe the wires leading in and out but think that will be tedious to work out.

What might work better, IMO, will be to identify the junctions (in photos) by an identification number, then use that with a legend. I'll try to post both examples soon to see what others think about the utility of the two possibilities or perhaps suggest something else.
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post #9 of 9 Old 10-15-2014, 01:37 PM
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Incredible Job

What a great job. As an owner of a Gen 2, I am jealous!
Your documentation and layout are excellent and the photos make it so any KLR owner could work on their bike.
Very, very impressive!

[email protected]
2009 Kawasaki KLR 650

always tinkering!
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