Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Kawasaki Tech
Kawasaki Tech Kawasaki Tech Forum - For Questions specific and of interest to Kawasaki riders only.
Photo by Daniel Rintz, Himba children, Namibia

The only impossible journey
is the one
you never begin

Photo by Daniel Rintz,
Himba children, Namibia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 30 May 2009
Registered Users
HUBB regular
 
Join Date: Jun 2008
Location: NSW, Australia
Posts: 62
'06 KLE headlight fixed!!!

Evening all,

Spent a couple of hours this arvo fixing my KLE's shortcomings after converting to a HID setup.

As you all will be aware the '06 model has indepenant lights, one for low beam and one for high. For the princely sum of $15.85, which purchased some wire, heatshrink and a relay (I had some wire cutter/strippers and solder/soldering iron and various connectors lying around) I converted the independant lights to a genuine hi/low beam setup.

This is due to the number of homicidal/suicidal kangaroos in my neck of the woods at present, especially after dark, and the latent warm up time of HID globes.

Basically the fix is done by tapping in to both the high and low beam circuits and inserting a relay which runs power directly from the battery (fused) to the low beam once the high beam is switched on. I figure that the draw from a single 55W globe is not so much less than 2x 35W HID's since they only draw 2W each once warm.

Tested it tonight and it worked like a beaut.

Might take some pictures and draw some mud-maps if anyone is interested....

Cheers
Ian
Reply With Quote
  #2  
Old 31 May 2009
AussieMasada's Avatar
Registered Users
New on the HUBB
 
Join Date: Mar 2007
Location: Honiara, Solomon Islands
Posts: 15
Some pics would be great. I am still toying with the idea of keeping my KLE and doing some ADV mods to it and buying a quad as a toy ot buying a KTM or BMW when I return home from working OS.

The more I read about what other KLE riders in the world are doing with thier bikes, I am really seriously considering keeping the KLE. Have you seen Adventure MX KLE 500

Happy riding
__________________
I have only one eye. Do you want me to look at the road or at the speedometer. Moshe Dayan

חובה
גאווה
כבוד
שנפלו הלוחמים עבור
Reply With Quote
  #3  
Old 4 Jun 2009
Registered Users
HUBB regular
 
Join Date: Jun 2009
Posts: 32
Hey where in NSW are you??

I just relayed my high beam, will also set it up to run low beam.

The stator puts out about 230W so there would be no issue running two halogens even, as long as its through a relay from the battery.
Reply With Quote
  #4  
Old 4 Jun 2009
Registered Users
HUBB regular
 
Join Date: Jun 2008
Location: NSW, Australia
Posts: 62
Jimmy101,

Am in Gulgong...

No real need for pictures of the install, but it works like this...

Run a fused wire from Battery +ve along the existing wiring loom up to the heatlight region, this wire goes to the supply side of the relay. Next you need to tap into both the low and high beam power feed wires behind the headlight (before the HID conversion wiring) so that the mod works even after the HID is removed. The switched battery power from the relay is wired to the LOW beam power feed wire. The high beam power feed wire is taken to the relay and used as the exciter wire to pull the relay in when the high beam is switched on. All that is left to do is earth the remaining leg of the relay. Doing it by numbers is simple enough:

pin 87 to low beam feed
pin 30 to fused battery +ve
pin 85 to ground
pin 86 to high beam feed

Relay just gets cable tied to the headlight support bracket and wiring neatly taped/tied up.

Cheers
Ian
Reply With Quote
  #5  
Old 5 Jun 2009
Registered Users
HUBB regular
 
Join Date: Jun 2009
Posts: 32
I like to keep my relays under the seat - each to their own, but seeing as your tapping into the plugs up there I suppose its a good spot. Thanks for info.

By the way all Narva do a relay with a 30 amp blade fuse in it!. very neat solution as you dont need to attach any in-line fuse. Most Repco shops have them in AUS.
Reply With Quote
  #6  
Old 5 Jun 2009
Registered Users
HUBB regular
 
Join Date: Jun 2008
Location: NSW, Australia
Posts: 62
Quote:
Originally Posted by jimmy101 View Post
I like to keep my relays under the seat - each to their own, but seeing as your tapping into the plugs up there I suppose its a good spot. Thanks for info.

By the way all Narva do a relay with a 30 amp blade fuse in it!. very neat solution as you dont need to attach any in-line fuse. Most Repco shops have them in AUS.
Ahh yes grasshopper (RIP David Carradine), provided the relay is mounted close to the battery!

Being a renowned tight-arse Kawasaki owner I was saving on the cost of copper wire (doing my bit for the planet you know!), and used a "recycled" fuse holder for the wire close to the battery...

Cheers
Ian
Reply With Quote
  #7  
Old 12 Feb 2010
Registered Users
HUBB regular
 
Join Date: Dec 2009
Posts: 27
Question for Ian

Gidday Ian

You mentioned on here you did a HID conversion on your KLE... got any details?

With fitting my fog lights as I mentioned in another post I have come up against the limitations of the KLE alternator output and will be replacing the 55w bulbs with 35's.

How do you find the headlights woth the HID setup? I read once that HID conversions don't work well going into a reflector designed for halogen bulbs but I do like the idea of lowering the headlight wattage

cheers
Tracy
Reply With Quote
  #8  
Old 15 Feb 2010
Registered Users
HUBB regular
 
Join Date: Jun 2008
Location: NSW, Australia
Posts: 62
I am certain I wrote something up on it here - or it might have been on the ADV rider site...

Anyways bought a cheap set from ebay (about $140.00) from memory, ultra-slim ballasts are the ticket!



Inside the box


Comparing the globe focal points - they match!



Made up a nice mounting plate below the instrument cluster





Wiring is direct from the existing loom, although now modified as per the posts previous...

New globes in existing holes



Before Low beam



After Low beam


The light is a much brighter light cutting through the dark better than std. I suspect that the KLE reflectors work better than most for this purpose. It is also imperative that you are aware of headlight aiming, as these lights tend to be a little harsher on oncoming drivers if you are carrying a larger load on the bike. You will get "flashed" as they appear to be much brighter to other road users. I live in a 'roo infested area and we have the highest incidence of insurance claims for kangaroo strikes in NSW. To date the lights have more than paid for themselves in locating roos ahead and allowing me to stop/slow/avoid them.

I will be taking them with me if I replace this KLE with another, and the conversion will work identically with the KLR as the lights are the same

Cheers
Ian
Reply With Quote
  #9  
Old 27 Feb 2014
Registered Users
New on the HUBB
 
Join Date: Oct 2012
Posts: 1
Thanks

[QUOTE=Jameseye;244622]Jimmy101,

pin 87 to low beam feed
pin 30 to fused battery +ve
pin 85 to ground
pin 86 to high beam feed

Relay just gets cable tied to the headlight support bracket and wiring neatly taped/tied up.



I know it is an old post but still relevant.
Thanks Ian for the heads up on this.
Bought an '07 KLE500 for my eldest and have been annoyed by the poor lighting.
Have done your suggested fix to have both high and low remain on when switched to high beam.
Also have mounted LED driving lights separately wired and relayed to fit with law and minimise strain on charging system.
Love the ide of running HID high only so as not to get the attention of the law.

Again thanks for sharing.
Reply With Quote
  #10  
Old 30 Mar 2014
Registered Users
HUBB regular
 
Join Date: Jun 2008
Location: NSW, Australia
Posts: 62
Must have Jonah'd me with the last post; the low beam ballast has shite itself and I have another on order (and my haven't prices dropped!) $20 for a locally stocked ballast via ebay

This is without doubt the best mod for the KLE in terms of night time ridability and safety (being seen)

Cheers
Ian
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
kawasaki f7 headlight randy Kawasaki Tech 0 22 Apr 2007 20:18
3AJ Headlight Question MotoXT Yamaha Tech 4 11 Apr 2007 21:03
Twin headlight for klr 650 HELP!! klrcelt Kawasaki Tech 1 18 Jan 2007 10:58
Attaching Panniers- Quick Release or Fixed? G. Kennedy Equipping the Bike - what's the best gear? 14 22 Mar 2005 03:13
CFA/Euro Exchange Rate Fixed? Ian North Africa 1 15 Jul 2002 14:46

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now
, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.




All times are GMT +1. The time now is 05:39.