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Old 04-27-2005, 06:38 PM   #1
irlsanders OP
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Location: SFV, Los Angeles, CA, USA
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KLR Electrical Gurus?

I'm making plans to do some electrical upgrades to my 2003 KLR650, as follows :

New Electrex G451 Stator and Regulator/Rectifier (400 watts at 2000 rpm)

Upgraded headlight harness, feeding HID conversion

Power outlet in the left side panel for battery charging or jumpstarting

Power outlets at the bars for a five-way volt/temp meter, heated vest,
,GPS , ipod, and a yet to be determined bike-to-bike comm system.

Heated Grips

Louder horn

My questions are :
Can the stock wiring harness harness all this draw?
What devices require switches and/or relays and fuses? What ratings?
If many relays and fuses are needed, where do they all go?
Is there such a thing as multiple relays in a single housing?
What connectors to use - Molex, spades, bullets?
What is a soild state relay? How reliable?
http://www.comagination.com/relay-kit-motorcycle.htm

Am i leaving out any other cool mods?

Thanks in advance for any advice.
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Old 04-27-2005, 07:02 PM   #2
Frank Warner
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Quote:
Originally Posted by irlsanders
Is there such a thing as multiple relays in a single housing?

What is a soild state relay? How reliable?
Yes there are such things as "multiple relays in a single housing" but I'd advise you to use single relays - all of the same type as presently used on your bike. Why? Because it means you only have one type for relay - they can be swaped around to find a fualt. If you have more than one type of relay you will have a fault where the relay is the only one of that type you have. Keep them all the same and seperate. Might be more money but it is a lot less frustration!

Solid state relays don't have a 'points' type contact - they use a semiconduuctor to do that part of the job. They should be more reliable. They are also more expensive, will fail totaly if overloaded (think a short to the frame) and harder to get in the never never. Some old fashioned relays can be pulled apart and cleaned if you are desperate to get them going so you can get home, you cannot do that with a soild state relay.

Don't think - cool - think "Less is more, less is more" Hell it is a KLR not a crotch rocket, pan earth tourer or lowrideing crusier.
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Old 04-27-2005, 07:06 PM   #3
irlsanders OP
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Good point about individual and identical relays, Frank.
Thanks. I am planning on riding it to Panama.
Maybe not "pan-earth", but pan-peninsular, at least!
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Old 04-27-2005, 07:26 PM   #4
Frank Warner
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I'd not do the HID conversion. You should not be riding at night - you'll miss the views. Spend the money on panniers, fuel and/or beer.

For power outlets at the bars I'd have one each for
heated vest,
GPS and
ipod.

You may like to put the heated vest outlet under the seat near your thigh to keep the lead shorter. This would also do for the battery charging .. but not jump starting - you need something capable of 100 amps for that.


I'd hard wire the volt/temp meter and a yet to be determined bike-to-bike comm system.
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Old 04-27-2005, 08:47 PM   #5
irlsanders OP
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I commute pretty often at night, and have gotten off a trail far later than expected, and better lighting seems worthwhile for those times.

Are any sockets rated for a jump, ir should that only ever be doen straight to the battery terminals?
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Old 04-27-2005, 11:21 PM   #6
fixer
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Quote:
Originally Posted by irlsanders
Are any sockets rated for a jump, ir should that only ever be doen straight to the battery terminals?
Anderson Power Poles. the large versions are used for QD jump cables on wreckers and some cop cars. also used for reciever mount winches. there's a smaller version that should work well for jumping a bike. i have a 1KW genny that uses them for jumping/boosting batteries.
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