Console construction - Kawasaki KLR 650 Forum
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post #1 of 42 Old 10-09-2012, 06:02 PM Thread Starter
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Console construction

I started making a fiberglass handlebar console. It is supposed to be waterproof...we shall see. I plan on installing a "Digital 5-Function Voltmeter" from "California Sport Touring, Inc." ( which is lighted but NOT waterproof. I also plan on installing several other electrical plugs/access connectors.

Lets see how it goes.

Last edited by gaucho10; 10-17-2012 at 06:20 PM.
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post #2 of 42 Old 10-09-2012, 07:54 PM
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Now that looks like something I could make but I don't think you are finished and I would be.

You would do Red Green proud.

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post #3 of 42 Old 10-11-2012, 10:05 AM Thread Starter
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Next phase...

So after the shell and layering of matting has cured I worked on the base.

First layer of matting over cardboard.

Several layers of matting curing in the sun.

Last edited by gaucho10; 10-17-2012 at 06:20 PM.
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post #4 of 42 Old 10-12-2012, 08:43 PM Thread Starter
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Electrical wiring for console...

While I'm waiting for the console fiberglass resin to cure I decided to start working on my electrical wiring. I have followed instructions somewhat from but have altered some things to fit my taste.

I plan on having possibly 3 "switched" and 3 "un-switched" accessory outlets. One will be for my lighted "clock, thermometer, volt meter" display, and one will be for trickle charging my battery. The rest will be for GPS, Radar Detector, cell phone charge, sonar, missile launcher, etc.

The first pic shows the white wiring coming from my "switched" plate light wire and up on top of the battery. Leading from the battery I have a 30A inline fuse (red), a negative (black) wire and the white platelight wire that is going to travel under the gas tank and into the handlebar console. I already purchased all the necessary materials to build my distribution block. Stay tuned...

Here we see the in-line 30A fuse and the battery connections.

While I had the ferrings off to run the wires under the gas tank I thought it would be a good time to replace my original horn. I think the original horn sounds so tinny so I purchased a 130 dB horn from NAPA. Sounds good now!!!! For horn installation check the "What did you do to your KLR today" thread @

Last edited by gaucho10; 10-18-2012 at 03:54 AM.
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post #5 of 42 Old 10-12-2012, 08:50 PM Thread Starter
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BTW...anybody have any ideas as to what type of plugs to use. I know that a GPS usually plugs into a cigaret lighter and a jacket liner and electric gloves have a different type of plug. I was hoping to find some sort of UNIVERSAL attachment...other than having 6 cigaret lighters available
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post #6 of 42 Old 10-12-2012, 10:12 PM
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gaucho10 -

I may be a bit late to this party...

The GPS is best hardwired. A cigarette style adapter just doesn't grip well enough to insure that the plug will maintain contact.

The typical heated gear plug is a Powerlet, also known as a BMW connector. It has a very positive engagement.

I have both the cigarette style and the Powerlet. The ciggy style is useful for using when stopped to charge my phone or Sena. The Powerlet runs my compressor and is available for heated gear, which I ain't got.

If you have to use connectors anywhere, I recommend the WeatherPak connectors. Rumor has it that some NAPA stores will carry them. If not, they are available on line from a multitude of sources. I recently bought some from Hi Po Parts and was satisfied. WeatherPak also make a neat fuse holder so you don't have to deal with pigtail soldering or crimping.


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Last edited by Tom Schmitz; 10-12-2012 at 10:14 PM.
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post #7 of 42 Old 10-12-2012, 10:28 PM Thread Starter
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Tom Schmitz---I was not planning on plugging the GPS into a cigarette lighter because I don't have room in my console for that. I was just being facetious. As a matter of fact, I don't even have a GPS at present. Just thinking for the future.

I am planning on running a relay/distribution block inside of my console so that I don't have wires all over the place. The GPS will be wired directly to the "block" unless I can find some type of "quick-disconnect" similar as on the electric gloves/liners.

I will definitely be checking into the WeatherPak connectors
I am sure there is something out there that I will find useful.

BTW...the reason for building this "console" is just for keep the electrical wiring clean, neat and easily accessible instead of "under the seat".
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post #8 of 42 Old 10-14-2012, 09:11 AM
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You might want to keep in mind that some GPS's ( like Garmin ) may have some type of voltage conversion built into their cig. lighter plugs. Cuting a GPS's power cable may not be compatable with the bikes 12 - 14 volts. Just some thing to consider!

White Horse Gear catalog has a good section on different types of power connectors.

Plus lot's of other things for bikes.

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post #9 of 42 Old 10-14-2012, 11:07 AM Thread Starter
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larry41, good point about the cig/lighter plug. I'll keep that in mind.
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post #10 of 42 Old 10-14-2012, 11:14 AM
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I have also seen Garmin units being powered by USB, so maybe including dedicated USB charge ports would be useful. I have a 12v power port (CIG) and have a USB adapter for it to charge my cell phones and cameras.

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