Wiring Plug Pin Outs- Gen1 - Kawasaki KLR 650 Forum
How To's & Tech Guides Post your mod how to's and tech guides here. Topics will be locked only to allow editing by original author.

 
LinkBack Thread Tools Display Modes
post #1 of 8 Old 06-20-2014, 11:39 AM Thread Starter
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
Wiring Plug Pin Outs- Gen1

Here is a rough (I did it so "rough" is an understatement) sketch of the wiring plugs, located under the front of the instrument cluster. They are viewed as standing in front of the bike, looking back.

Last edited by klr4evr; 06-20-2014 at 05:53 PM.
Normk is offline  
Sponsored Links
Advertisement
 
post #2 of 8 Old 06-28-2014, 01:30 PM Thread Starter
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
Well, Dropbox account, uploaded photos and then tried to copy a link but just receive a circling ring on and on, so some problem remains. One step closer though. I just bought a new laptop but not finished set-up. Maybe the extra horsepower will do the job?

Apologies and thanks for tolerating the sidetracking.



Main wiring plugs under the dash:
The plugs, viewed from the font of the bike, looking toward the rear are identified in the Clymer manual left to right as A, B, C, D, & E.

Plug A is a six pin. Pins are numbered in rows starting at the top, left.
1- Yellow/Red
2- Black/White
3- Brown
4- empty
5- Blue
6- Black/Yellow
\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\
Plug B is a nine pin. Pins are numbered in rows starting at the top, left.

1- Brown/White
2- Black/Yellow
3- Red
4- Grey
5- Red/Black
6- Light Green
7- Green
8- Yellow
9- Black

\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\
Plug C is a six pin. Pins are numbered in rows starting at the top, left.

1- White
2- Black/Yellow
3- Red/Yellow
4- Brown
5- Black/White
6- Red

\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\
Plug D is a nine pin. Pins are numbered in rows starting at the top, left.

1- Red
2- Red/Black
3- Green
4- Black
5- Black/Yellow
6- Orange
7- Red/Yellow
8- Blue/White
9- Grey

\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\
Plug E is a three pin. Pins are numbered in rows starting at the top, left.

1- Light Green
2- Blue/Red
3- Black/Yellow
Normk is offline  
post #3 of 8 Old 06-28-2014, 05:15 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,275
ATTENTION!!!!!!!!!!!

Any moderator within reach of my keyboard!!!!!!!!!!!

STICKY this thread here, or in "How-to's and Tech Guides!"

Good work, Normk; thanks!
Damocles is offline  
 
post #4 of 8 Old 06-28-2014, 06:17 PM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,335
I would second the comments of Damocles. This is valuable information Normk has taken the time and trouble to provide here. It is appreciated!



planalp is offline  
post #5 of 8 Old 07-20-2014, 02:16 PM Thread Starter
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
My son tells me that he may have a solution to my problem of having Drop Box images show up in my posts rather than simply showing the links. That may solve that annoying whining noise you hear from time to time. ;-)

I thought it might be useful to post the VRR pin out with a bit of explanation. I will try to post a photo/sketch later to see if that works.

Gen1 VRR (Voltage Regulator Rectifier) is located under the seat with the plug directed to the left side. Facing the plug, there are two rows of three wires, one row above the other.

Top row 1, 2, 3
Bottom row 4, 5, 6

1- White- power output wire to system +
2- Brown with white tracer- voltage reference or sense wire to wiring harness
3- Black with yellow tracer- ground wire to common ground & frame

4, 5, 6 - Yellow- stator output wires which bring AC from the stator. These can be in any position.

I will write a detailed charging system analysis and post to a separate thread. IME, these descriptions help to diagnose by increasing understanding.
Normk is offline  
post #6 of 8 Old 12-20-2014, 04:59 PM Thread Starter
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
A little this and a little that, back and forth

"Well, that's quite a switch!" Tom said electrically.

Tom

Overcame your resistance, I see. ;-)

Charge! I have a battery of electrical puns. :-)

"But, what is that switch in the link intended for?" Tom toggled...

Tom

There must be a multiple clip board turned on because it was supposed to be an updated link to the Gen1 wiring information. Sorry for my confusion.

The switch is for a CDI coil tester which I posted elsewhere. I made three of them yesterday, two for technician friends. It used a resistor to limit capacitor charging rate, a diode in series with that to 1/2 wave rectify, the DPDT switch alternates connecting a capacitor between (normally closed) 120 Volt AC and (normally open) a pair of jumper leads connected to the CDI ignition coil. Hook up to coil, hook up spark plug or spark checker to coil lead and ground, plug in tester to AC, wait a few seconds then push button and see spark from spark plug or spark checker. Repeat.

I thought you were making electrical puns, Tom.

"I'm shocked that you would think I'd ever be less than entirely serious", Tom said in an electrified tone.

By the by, a good job on the pin-outs and pictures. I really should get going on the Gen2 harness but I'm afraid if I did I'd lose steam on the oil pressure experiments (as if I'm moving out on that, even).

Now, I'm going to do a wee shuffle and pull these posts into one post.

Tom

Last edited by Tom Schmitz; 12-20-2014 at 06:19 PM. Reason: Was a bit of a divergence
Normk is offline  
post #7 of 8 Old 12-20-2014, 07:25 PM Thread Starter
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
I can't understand why no one has offered to take some photos of the bike wiring. That would get things going. I understand the time and energy balance so wouldn't want you to divert from the oiling project as best to get one completed rather than to have two in moth balls. I can likely find someone around here to strip off the Tupperware and that would likely be the best as can do the wiring color and positions easier directly.
Normk is offline  
post #8 of 8 Old 12-20-2014, 08:21 PM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,522
Garage
Aw, let's let it lie for a bit. I have the Gen2 and an extra harness. It won't take much once I get started on it and all the pictures will be in the same lighting and such like that.

Tom

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 online now  
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
Red Gen1 Maverik You've been spotted 0 06-22-2013 11:04 PM
Oil Filter Mounting Pin Dualie 1987 to 2007 Wrenching & Mods 18 05-07-2013 09:21 PM
Oil Filter Pin Bigrockindaddy 2008+ KLR650 Wrenching & Mod Questions 6 05-05-2011 12:38 PM
Gen1 vs Gen2 in the rain. AJay112 KLR & Other Motorcycle Related Discussion 5 04-23-2011 07:32 PM
Six Gen1's in downtown Flagstaf jtope28 You've been spotted 3 10-01-2010 03:30 PM

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