klr wiring identification
Posted: Sun Sep 14, 2014 12:54 am
Here are draft copies of the wiring harness ID project. This required many, many hours and am cross-eyed from checking but should be correct. Huge thanks to Tom and Mike for their work. Tom took my "crayons on the bathroom wall" level sketches of the wiring plugs and transformed them into the excellent drawings shown. Mike spent several hours using the diagrams to search for components and going from components to the diagrams and found some errors in the process. Big thanks to both of them are in order. I tried to provide a cross-link by numbering and naming the components between the various pages. The Main Wiring plugs, for example are shown in a photo of the plugs in place, shown in the photo of the wiring harness laid out on the floor, labelled on the blanked out version of the wiring diagram, and in the description sheets describing location and pin outs by color. Please take some time to review these and offer suggestions for clarification, corrections and improvements. If someone is willing to improve the labeling, please let me know and we can arrange to get other photos to you if that will help. Apologies for some photos showing extra wiring as the bikes available right now are not stock. I did substitute a VRR area photo from Mike's bike to replace mine which has a mass of extra wiring in the area. My plan is to further develop this project bu stripping the loom from the harness I bought in order to both diagram and show photos of the routing and connections for each wire. I'm not aware of anyone who has the various wire interconnections within the harness covering shown. Sorry my messages are so "wordy" but try always to be as clear and complete as possible. The various pages are in order as in the file so they may not seem to be in the order most desired. I encourage downloading and printing/storing these if wanted in case a DropBox link is changed or dropped in future. My intention is to try to make this easier for my friends. Fan area photo:
https://www.dropbox.com/s/6vo9s437po174ml/Cooling%20Fan%20Labeled.jpg?dl=0 Plugs (shown from the wire end of the plug unless noted):
https://www.dropbox.com/s/sge5s1ixqy4oex1/KLR%20Gen%201%20Pinouts%202_Page_1.jpg?dl=0 https://www.dropbox.com/s/kgj5h6fms4kf7cm/KLR%20Gen%201%20Pinouts%202_Page_2.jpg?dl=0 Wiring diagram:
https://www.dropbox.com/s/8p3epo7uuraysf5/KLR650%20Wiring%20Diagram.jpg?dl=0 Wiring diagram blanked to show only plugs:
https://www.dropbox.com/s/d0qoelx8w8hj9s2/KLR650%20Wiring%20Plug%20Identification.jpg?dl=0 Main wiring harness plugs:
https://www.dropbox.com/s/orzg8qgepd69jgf/Main%20junction%20plugs%20labeled.jpg?dl=0 https://www.dropbox.com/s/qkbnl1wf59g8oep/Main%20wiring%20plugs%20under%20the%20dash2.doc?dl=0 Starter relay area:
https://www.dropbox.com/s/t0beqjhq2jtx8aa/Starter%20Relay%20Area%20labeled.jpg?dl=0 Steering head wiring area:
https://www.dropbox.com/s/1eu6r2oiz5st7s0/steering%20head%20area%20wiring%20labeled.jpg?dl=0 Lower steering head wiring area:
https://www.dropbox.com/s/0zt7ycavsepc4gp/steering%20head%20area%20wiring%20lower%20labeled.jpg?dl=0 https://www.dropbox.com/s/rsvmbie0nldfum5/Trigger%20Coil%20Neutral%20Switch%20labeled.jpg?dl=0
Under seat/VRR area:
https://www.dropbox.com/s/qhvmi8egm639owj/VRR%20area%20labeled%20%282%29.jpg?dl=0 Wiring harness labeled:
https://www.dropbox.com/s/3rssy176rodxzva/Wiring%20harness%202%20labeled.jpg?dl=0
Comments? How do we improve this?
I will be improving/correcting and adding to these over the next while so please recheck them from time to time for changes.
Norm
