KLR650 Wiring Plug Identification

[Norm]

I'm working on identifying the wiring component locations, junction locations, ground locations, etc. for the KLR650. Very often someone posts a problem to a web group but it is difficult to help unless one can give details.

The wiring diagrams give the wire colour codes (wire jacket colour first/tracer stripe second. i.e. White/Red) but so far as I know there is not breakdown for which plugs the wires terminate into, or where the wires are located in the plugs. This makes it more difficult to trace the wiring. In an effort to assist with this issue, please find below the locations for the wiring plugs under the instrument cluster and the layout of the wires in the plugs.

I will continue to identify other aspects as time and motivation allow.

HIH
Norm

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

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PlugB is anine 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



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PlugC is asix 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



\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\

PlugD is anine 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



\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\

PlugE is athree pin. Pins are numbered in rows starting at the top, left.



1- Light Green

2- Blue/Red

3- Black/Yellow

 

[Yak_KLR650]

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Thanks for sharing Norm! I wish I had your attention for detail!

 

[Norm]

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Attention to detail or obsessive/compulsive..... (VBG)

Glad to be of service. I'm hoping that Mark can post this info on his site also. As time allows I will try to identify the location of the other plugs and wiring junctions in the harness.

Unfortunately, I seem to have misplaced the measurements I took for the junctions leading off the White (main power) wire and the grounds in the centre section of the wiring harness when I had mine stripped apart. Now it may have to wait until someone else either does the same jobs or I do another one here.

If there was a breakdown available showing where all the wire junctions are, where the grounds connect, where all the wiring plugs are located and where each of the electrical components (such as signal flasher, diode set, etc.) are located, it would make life much easier for someone fighting an electrical issue at home.

It is less of an advantage for a well trained tech with a lot of exeperience but sure can help when trying to advise someone by email. I do a lot of that so the time spent will make it easier.

If anyone else can chime in and provide the locations for components, it would be helpful. I'm looking for the physical locations, with measurements from some obvious point as well as the shape of the wiring plug, number and orientation of the wires, and dimensions/description of each component. This kind of information would really help the guy who has no idea as to what the signal flasher looks like of where it is. Responses will often indicate the component likely to be at fault but people are often stuck because they can't find it.

Given the huge number of KLR wrenches out there, this should be a simple task.

Thanks for the encouragement,

Norm

 

[ScottyKLR650]

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old thread.. Norm, did you ever complete your task?

I just installed a pair of driving lights on my (two years new to me) '96 KLR, and inadvertently did a bit of damage to my wiring harness.. fried a wire somewhere in the headlamp circuit, and for some reason, lost my right turn signals as well (left signals still work, go figure)

anyone know if/how much a replacement harness goes for? the bike had at least 3 owners before me, at least one of whom screwed with pretty much all of it.. I think it might be time to just replace the whole thing and convert to modern ATO fuses on a panel (conveniently mounted!)..

cheers,
Scotty

additional, 12 days later... replacement main harness solved the problem $280+ from the nice green store.. cheaper than I thought it would be! haven't gone to a block as the one I had wouldn't fit between the frame rails, so I have 3 ATO/weathersealed inlines under there, extension leads so I can jump-start if I need to, and BRIGHT driving lights mounted to my tool tube! the re-wire only actually took about 3 hours, including dis/re-assembly!