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I'm freshening up the KLR with high hopes of doing 2 BDR's this summer and a few other over night rides. My KLR is 2008 with 12k miles on it. I bought it last year with 9k on it so figured I would go through and do the service bulletins, DooHickey, carb clean, airbox L mod jetting, and I put progressive fork springs and a top gun spring in the rear. I got it all apart last night and was inspecting wiring harness and came across two 4pin connectors like you normally see for small trailers. They're not connected to anything. In the brief searching I've done I don't see them as stock. Can someone tell me are they stock? What are they for?
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You will need to test the continuity to various circuits, but I'll suggest turn signals, brake lights, tail lights & their grounds for them that were probably mounted to saddlebags.
 
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+ 1; the connectors look an awful lot like the brake/turn/running light connectors on my motorcycle rail trailer.
 

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Discussion Starter #4
+ 1; the connectors look an awful lot like the brake/turn/running light connectors on my motorcycle rail trailer.
I have this connector on my moto trailer as well. Why the heck would someone put two of them on a KLR? Or is this somehow stock?
 

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They are not stock. They are trailer connectors and good for ground, right, left, and brake. @pdwestman makes a good suggestion that they were used to add aux signal lighting to a set of panniers.

They might also be set up for heated clothing, device charging in a pannier or tank bag, or controlling a small fusion reactor to provide electrical power at a level that the KLR's alternator cannot. They could be for anything.

I'd want them off of my bike because, candidly, they are the sign of a differently-abled wiring specialist. Their very use indicates that they have been spliced into the system, and likely not in a well-done fashion.
 

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Discussion Starter #6
They are not stock. They are trailer connectors and good for ground, right, left, and brake. @pdwestman makes a good suggestion that they were used to add aux signal lighting to a set of panniers.

They might also be set up for heated clothing, device charging in a pannier or tank bag, or controlling a small fusion reactor to provide electrical power at a level that the KLR's alternator cannot. They could be for anything.

I'd want them off of my bike because, candidly, they are the sign of a differently-abled wiring specialist. Their very use indicates that they have been spliced into the system, and likely not in a well-done fashion.
Kind of what I thought. I'm going to unwrap everything and see just how bad it is. I don't want to replace entire harness.. yikes.
 

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Discussion Starter #7
Making slow progress but did have time to dig into the wiring harness. As suggested the two 4pin connectors must have been used for external lights. They were connected to the blinker and tail light connections. I unwrapped everything to have a look and was pretty bummed on what I found. They spliced in really close to the OEM connector so I don't have enough wire to cut and re-do properly. One connection was already hanging by a thread and fell apart from the pull of the tape. Would love to hear thoughts on how you guys would go about patching this up.
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I would go to cycleterminal and get the new connectors that I needed, plus a few extra terminals, and a crimping tool and get the thing fixed up right. Joe's good people and runs a good business.

That connector is a Sumitomo HM 090 series 3-pin. They run about $3/connector with terminals, the extra terminals are about $.20ea, and a decent crimp tool is $34.

Joe will have every connector you would need for a KLR. I built an entire harness with the product he provided.

You can buy pin extractors and use them to remove the installed terminals from the connector body, then re-use the connector body, buying only terminals.

Alternatively, you can buy a replacement harness rather inexpensively and swap it out. You can even find butchered harnesses cheaply and use them to harvest OEM wire, though it is a bit of a fool's errand because the OEM harness has a large number of splices in it. There's not much long wire to harvest, but you can get the connector bodies easily.

I am not a fan of soldering wire terminals; I do crimp-only. I have professional soldering equipment, but only use it on PCB stuff, not wiring.
 

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Discussion Starter #9
Thanks Tom! This is awesome and one of the reasons I keep the KLR. The community is a huge benefit! I'm somewhat familiar with working with wire connectors so I have all of the tools but had no idea about cycleterminal.
 
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