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Old 06-21-2013, 07:52 AM   #4771
0theories
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Quote:
Originally Posted by wparkinson View Post
...

A while ago I went into the wiring harness to eliminate all the wires that weren't necessary. ...
Wait. There are wires that are not necessary?!? More info please
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Old 06-21-2013, 08:46 AM   #4772
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It will probably be easier for me to post a copy of my wiring diagram to explain what I've removed.

All the wires that are associated with the safety lockouts (neutral, sidestand). Turn signal..... and some others... I don't even have a key anymore....shhhh don't tell anyone...

I have a trailtech vapor so there are wires associated with the speedo that are no longer needed...

This type of mod is not for the faint of heart... There's a lot that can be screwed up by doing the stuff that I've done. But I have slimmed down the harness so there's just not as much garbage in there.

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Old 06-21-2013, 09:52 AM   #4773
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Quote:
Originally Posted by wparkinson View Post
But I have slimmed down the harness so there's just not as much garbage in there.

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Old 06-22-2013, 04:25 AM   #4774
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Originally Posted by 8lives View Post
Nice work wparkinson,Ive follow your KLR on the other sites and you do some good stuff,and ride it hard!
Thanks man I do what I can.... The KLR is a fun bike to have.. and Yes... I try to ride it hard....

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Old 06-22-2013, 05:44 AM   #4775
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I took the wiring diagram that is floating around the internet.. I am not sure who to give credit to but whoever did it I give major props to.. without it I would have been lost....

I found the diagram here.....http://www.wiringdiagrams21.com/2008...iring-diagram/

Here is my new diagram

KLR Wire 2-3 by sky_soldier_82nd, on Flickr

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Old 06-22-2013, 07:38 AM   #4776
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Originally Posted by wparkinson View Post
I took the wiring diagram that is floating around the internet.. I am not sure who to give credit to but whoever did it I give major props to.. without it I would have been lost....

I found the diagram here.....http://www.wiringdiagrams21.com/2008...iring-diagram/

Here is my new diagram


KLR Wire 2-3 by sky_soldier_82nd, on Flickr
Maybe Edwin Parkinson? lol
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Old 06-22-2013, 07:48 AM   #4777
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Well being I am Edwin Parkinson.. I know who did the one in the pic... I was referring to the one that is in the link...
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Old 06-25-2013, 11:05 AM   #4778
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Has anyone ever dealt with a foot peg nut that is dislodged (weld tack broken) I bought a 03' KLR and when I took the centerstand off I found that the previous asshole had broken the nut off inside somehow and I had to fight with the screw to get it out...now it won't go back in and catch the nut which has fallen down inside the mount.

I attached a pic but you can't see much. Looking at centerstand over the mount and you can just see in the very back the nut. I managed to get it into position a couple of times but it won't thread on. Any ideas?

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Old 06-25-2013, 11:21 AM   #4779
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Originally Posted by Lappeman View Post
Has anyone ever dealt with a foot peg nut that is dislodged (weld tack broken) I bought a 03' KLR and when I took the centerstand off I found that the previous asshole had broken the nut off inside somehow and I had to fight with the screw to get it out...now it won't go back in and catch the nut which has fallen down inside the mount.

I attached a pic but you can't see much. Looking at centerstand over the mount and you can just see in the very back the nut. I managed to get it into position a couple of times but it won't thread on. Any ideas?

Cut the face of the box off with a cut-off tool, weld some real nuts on the back there and weld the box back together.
That's the only real fix, and I'm sure that your friendly neighborhood welder can set you up pretty cheap-like.

For a cheap fix, you could weld the footpeg bracket to the box and call it a deal, that'll work forever if you have a decent welder do it. I had mine done in Gunnison, Colorado (I was on a trip) by a welder who was working on a shop full of farm machinery, that weld would have withstood a nuclear attack.

For the wrong fix, drill a hole through the frame there and run an extra-long bolt through the box and frame and put a nut on it. Like the dummy did that sold me an '04 parts bike.

Edit: I suppose you could also use a couple of Heli-coils, but you'd still have that nut rattling around in there...
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Old 06-25-2013, 11:46 AM   #4780
Kevan Garrett
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There is a link on klr650.net for addressing some of these issues.

Go to forums/Maintenance, Mods and Tech/Procedures and How-to articles/Footpeg bolts - Fix w/ HELICOIL or WELDING


Good luck.

Kevan


Quote:
Originally Posted by Lappeman View Post
Has anyone ever dealt with a foot peg nut that is dislodged (weld tack broken) I bought a 03' KLR and when I took the centerstand off I found that the previous asshole had broken the nut off inside somehow and I had to fight with the screw to get it out...now it won't go back in and catch the nut which has fallen down inside the mount.

I attached a pic but you can't see much. Looking at centerstand over the mount and you can just see in the very back the nut. I managed to get it into position a couple of times but it won't thread on. Any ideas?

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Old 06-25-2013, 11:53 AM   #4781
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CA stu got it right. ... I just did this. I drilled out the old nuts with a 3/4 hole saw.... took a piece of 1/4 in flat bar and welded the new nuts to the back of that and welded that on... google up klr foot peg repair and it will come up.

I wouldn't weld the foot peg bracket on because you can't get the motor out if needed....

WP

Link... you may have to be a member... if you have a klr and you are not then shame on you....
http://klrworld.com/forums/*-frame-h...r-by-michaeln/

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Old 06-25-2013, 03:27 PM   #4782
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Quote:
Originally Posted by wparkinson View Post
I took the wiring diagram that is floating around the internet.. I am not sure who to give credit to but whoever did it I give major props to.. without it I would have been lost....

I found the diagram here.....http://www.wiringdiagrams21.com/2008...iring-diagram/

Here is my new diagram

KLR Wire 2-3 by sky_soldier_82nd, on Flickr

I like this. My bike could use a serious re-wiring...I'm it's 4th owner, and the first owner did some serious hack job on it. It's an '08, and there is no fairing, headlight gone, no dash, gauges, windshield. IMS tank. Vapor computer. Trailtech headlight. the tab on the headstock that sticks out between the forks to mount things on has been removed with a sawzall. No sidestand switch, clutch switch, or neutral switch. Wiring is all screwed up - not looking forward to ever dealing with an electrical problem.
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Old 06-25-2013, 03:46 PM   #4783
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Go on ebay and get a new harness for less than 50 bucks... then take yours with a diagram and do what you want. I was never worried because a replacement is relatively cheap and available.

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Old 06-25-2013, 04:14 PM   #4784
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Quote:
Originally Posted by wparkinson View Post
Go on ebay and get a new harness for less than 50 bucks... then take yours with a diagram and do what you want. I was never worried because a replacement is relatively cheap and available.

Sent from my SCH-I535 using Tapatalk 2
do you mean a new harness, or 'another' harness? I don't see any new ones...only old ones with damage for $40-$80 with shipping from $40-$50.

To spend upwards of $120 for a broken used harness, I'd rather just take my time this winter with a good diagram, my soldering iron, and go from there - Make my own harness and shrinkwrap & loom the entire thing.
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Old 06-25-2013, 05:00 PM   #4785
wparkinson
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Originally Posted by LilGreenBooger View Post
do you mean a new harness, or 'another' harness? I don't see any new ones...only old ones with damage for $40-$80 with shipping from $40-$50.

To spend upwards of $120 for a broken used harness, I'd rather just take my time this winter with a good diagram, my soldering iron, and go from there - Make my own harness and shrinkwrap & loom the entire thing.
Here is one from an 09 would work...

http://www.ebay.com/itm/09-Kawasaki-...1decf3&vxp=mtr

I have bought from them... they good to deal with..

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