Gen 1 Fuses - Kawasaki KLR 650 Forum
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post #1 of 10 Old 04-23-2013, 03:08 PM Thread Starter
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Gen 1 Fuses

I have an '06 and do the occasional headlight fuse replacement, usually at a time of not my choosing A couple of years ago there was a site that sold flat-fuse attachments to relplace the glass fuses, wired for the gen 1. Now I can't find them nor anybody with a similar farkle. Does anyone out there know of one available? or a good source for a DIY version? I wouldn't mid running the fuses into under the kickstand switch cover either. Thoughs?
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post #2 of 10 Old 04-23-2013, 04:40 PM
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I've done a compete fuse relocate and replacement from the glass fuses to whatever those things are called now.

I got some waterproof fuse holders from a seller on eBay for the rad fan fuse and a kit from Totally Wired. Unfortunately TW is no longer selling these but our site sponsor Twisted Throttle is:

http://www.twistedthrottle.com/elect...-klr650a-86-07

eBay seller was GenuineDealz - http://www.ebay.com/sch/genuinedealz...&_trksid=p3686

You can also find some info here:

http://www.klr650.marknet.us/twcfusereloc.html

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 04-23-2013 at 04:42 PM.
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post #3 of 10 Old 04-23-2013, 10:32 PM
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yeah i used something like this:
http://www.ebay.ca/itm/10-x-WATER-PR...7cb326&vxp=mtr

just cut, solder and heat shrink the wires. mine are just barely hanging down under the right plastics under the seat. can change em out without ANY tools. dont have to remove plastics or seat.

also if 'glow if they blow' fuses are good in theory. if u blow a fuse in the middle of the dark they glow to show they are burned out. ( i too lost head light at a bad time camping in the middle of no where at night). but FYI then dont always glow

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post #4 of 10 Old 04-24-2013, 07:59 AM Thread Starter
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Thanks you guys! The Totally Wired rig looked really slick, too slick!( I'm looking for the easy way out of course. Plug and Play!) I should have bought one when they were still available (maybe I would have kept them in business?) Looks like I will have to piece mine together from the local Radio Shack bits and pieces.
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post #5 of 10 Old 04-24-2013, 09:38 AM
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Quote:
Originally Posted by Swaneez2 View Post
( I'm looking for the easy way out of course. Plug and Play!) Looks like I will have to piece mine together from the local Radio Shack bits and pieces.

You kinda contradicted yourself.

The Electrical Connection kit that is sold directly by them or Twisted Throttle is very similar to the one that came out of Totally Wired. Actually may be better because it includes the rad fan fuse and has connectors for plug and play. The TW setup required splicing and didn't include the fan unless you wired it yourself. I just relocated my fan fuse to the front where it was accessible.

Piecing it together isn't a great option. I couldn't find the triple fuse holder anywhere and there likely would be more splices involved. I have used EC products on my Goldwing. Top grade stuff.

http://www.electricalconnection.com/...sses/08106.htm

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #6 of 10 Old 04-24-2013, 09:41 AM
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A good way to prevent, or at least reduce, blown Generation 1 headlight fuses, glass OR blade, is:

Use a 15-amp, vs. a 10-amp, fuse in that location!

Why?

The Generation 1 HIGH/LOW headlight beam switch may momentarily engage BOTH filaments when switching; this current load sometimes blows the OEM 10-amp fuse.

Blade fuses doubtless are an improvement; a higher-rated headlight fuse, however, should address your immediate problem without requiring the electrical retrofit of converting to blade fuses, IMHO.
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post #7 of 10 Old 04-24-2013, 10:20 AM Thread Starter
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Gen 1 Fuse

There we go! Thanks, KLR4evr, the Electrical Connection kit is exactly what I was looking for. I havn't been able to open Twisted Throttle web site for a while (not sure why) so I couldn't check what they had, but the EC site is new to me, and like you said, their setup looks pretty much like the TW one.
And Damocles is right too about both filaments connected for a nanosecond, though I have had the headlite just go out when it darned pleased. Nothing is perfect but will be less un-perfect the more farkles we have. I think I read some ancient proverb about that somewhere. happy riding
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post #8 of 10 Old 04-24-2013, 12:14 PM
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What I used for the rad fan is something like this and then just mounted it on the front .







.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #9 of 10 Old 04-24-2013, 04:57 PM
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Quote:
Originally Posted by Swaneez2 View Post
And Damocles is right too about both filaments connected for a nanosecond, though I have had the headlite just go out when it darned pleased. Nothing is perfect but will be less un-perfect the more farkles we have. I think I read some ancient proverb about that somewhere. happy riding
Whether blade or glass fuses, Swaneez2, I'd recommend a 15-amp fuse for your headlight circuit. Don't think you'd compromise safety (understand Generation 2 have 15-amp headlight fuses, but I ain't sure), and . . . you might cut down on the number of blown headlight fuses by upgrading yours.
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post #10 of 10 Old 05-02-2013, 02:33 PM Thread Starter
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Gen 1 fuses

Thanks gentlemen, all great advice. I've thrown in a 15 amp fuse for now and will likely order the wiring kit, or perhaps make my own flat fuse set-up with additional connections for jump starting (another issue). The sky's the limit when it comes to KLR mods.
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