New electric box w/bus - Kawasaki KLR 650 Forum
Gadgets & Gizmos Discussion on the latest "toys" to enhance the adventure.

LinkBack Thread Tools Display Modes
post #1 of 1 Old 01-19-2014, 03:09 PM Thread Starter
2nd Gear
Grinnin's Avatar
Join Date: Feb 2013
Location: Maine
Posts: 368
New electric box w/bus

I reworked my "dashboard". I'll describe what's there now but first I'm telling what was there and why I reworked it.

I've had a dashboard that used the same bolts as the headlight rear cover (1st-gen). It included a relay powered by the "city lights" wires that are unused up front. The relay turned on power to the outlets for the GPS and heated jacket. The "real" power comes from a 10 gauge pair that's fused at the battery.

The 5-function meter (or 5-malfunction meter) is right about 95% of the time. It doesn't have an indicator telling if the current display is part of the 5% or the 95%; i.e. it's not possible to know if it is right or wrong. The clock may keep perfect time for a week then lose 40 minutes one day. The temperature and voltage are also unpredictable. Yes, I siliconed the inside -- there are too many switches that expose the circuit board to outside humidity for that to work for me.

The jacket outlet on the dashboard was just barely in reach but the springy coiled cord on my jacket would pull the plug out of the outlet. I added a second outlet zip-tied to the handlebar. That worked better.

The cig outlet vibrates enough to eject any plug.

When I was stopped for a week I needed an always-on cig outlet. I rewired it, but it was more trouble than it should have been. You can see electrical tape in the pic below and that is from changes. The dashboard WAS almost all soldered connections and not made to be reconfigured.

I decided to make a box that was
  • closer
  • used Powerlet outlets
  • more reliable display
  • reconfigurable

I wanted to keep it all on a single inline fuse at the battery.

Here 'tis:

It has only a volt display. Note the display is NOT rectangular, but the top and bottom are bowed in. I like the small (7mm or .28") digits and it has been accurate so far. It's a SMAKN display from Amazon.

The inside uses 3 bus blocks. I cut the metal parts out of terminal strips and soldered them together. The bus blocks are, from left to right, ground, switched power, and always-on power. The plan is to embed the bus blocks in something more solid, but for the end of last year I just had them zip-tied to a piece of plastic with an inner-tube cover.

So that's my report on the mistakes I made in the past and the new direction for mistakes in the future.

Last edited by Grinnin; 01-19-2014 at 03:11 PM.
Grinnin is offline  
Sponsored Links

Quick Reply

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


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

Email Address:


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
Electric help Two Brothers 1987 to 2007 Wrenching & Mods 3 08-20-2013 09:51 PM
Bus trip uk trailer guy Jokers Lounge 1 05-28-2013 06:40 PM
no electric !!!!! clayman 2008+ KLR650 Wrenching & Mod Questions 6 05-15-2010 09:33 AM
Electric Daddyjoe Southeast Riders 4 12-11-2006 08:09 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