Denali DialDim User manual

Instruction Rev00
0mm 10 20 30 40 50 60 70 80 90
Thank you for choosing DENALI
We know you would rather be riding your bike than wrenching on it, so we go the extra
mile to make sure our instructions are clear and as easy to understand as possible. If
you have any questions, comments, or suggestions don’t hesitate to give our experts
a call at 401.360.2550 or visit WWW.DENALIELECTRONICS.COM
Please Read Before Installing
DENALI products should always be installed by a qualified motorcycle technician. If
you are unsure of your ability to properly install a product, please have the product
installed by your local motorcycle dealer. DENALI takes no responsibility for damages
caused by improper installation. Caution: When installing electronics it is extremely
important to pay close attention to how wires are routed, especially when mounting
products to the front fender, front fork, or fairing of your motorcycle. Always be sure
to turn the handlebars fully left, fully right, and fully compress the suspension to
ensure the wires will not bind and have enough slack for your motorcycle to operate
properly.
Installation Tips
We strongly recommend using medium strength liquid thread locker on all screws and
bolts. It is also important to ensure that all hardware is tightened to the proper torque
specifications as listed in your owner’s manual. For included accessory hardware
please refer to the default torque specifications provided below. Inspect all hardware
after the first 30 miles to ensure that proper torque specifications are maintained.
Hardware Sizing Guide
Not sure what size bolt you have? Use this ruler to measure screws, bolts, spacers, etc.
Remember, the length of a screw or bolt is measured from the start of the “mounting
surface” to the end of the screw, so only include the screw head when measuring
countersunk screws.
M3 10.0 in-lbs - 1.0 Nm
M4 23.0 in-lbs - 2.5 Nm
M5 44.5 in-lbs 3.5 ft-lbs 5.0 Nm
M6 78.0 in-lbs 6.5 ft-lbs 9.0 Nm
M8 - 13.5 ft-lbs 18.0 Nm
M10 - 30.0 ft-lbs 41.0 Nm
M12 - 52.0 ft-lbs 71.0 Nm
in-lbs
ft-lbs NmBolt Size
0in 1 2 3
What’s In The Box?
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Instruction Manual
(a) DialDim™ Wiring Harness.....................................................Qty 1
DialDim™ Wiring Harness
Kawasaki KLR650
DNL.WHS.21900
OUTFITTING
GUIDE

This DialDim Wiring Harness enables plug-&-play connection between our
standard DialDim Lighting Controller and the Kawasaki KLR650. The
harness replaces the universal posi-tap style input harness that is included
with the universal DialDim Controller, enabling you to simply connect in-line
at the factory headlight, horn, and turn signal connectors.
For a detailed overview of the installation, including an in depth wiring
overview video, visit the link below:
WWW.DENALIELECTRONICS.COM/OUTFITTINGGUIDE/KLR
The KLR650’s battery is located towards the rear, underneath the left hand
side cover of the motorcycle.
Step One: To gain access to the battery, remove the left hand side cover
by removing the factory bolts, washers and collars from the cover. Pull the
cover outwards and towards the rear of the motorcycle to remove.
Step Two: Remove both of the terminals from the battery, starting with
the positive +(Red Terminal).
The DialDim Controller will be positioned towards the rear of the
motorcycle, under the passengers area of the seat.
Step Three: Remove the seat by removing the two bolts, collars and
dampers from either side of the motorcycle. Lift up the rear part of the seat
and pull towards the back of the motorcycle to remove.
Step Four: Position the DialDim Controller underneath the passengers
area of the seat and begin routing the battery leads towards the battery.
Step Five: Remove the fuse from the DialDim fuse holder, then connect
both of the battery leads to the battery, starting with the ground -(Black
Terminal). Then re-install the fuse to the DialDim Fuse holder.
Step Six: Use double-stick tape and/or zip-ties to securely mount the
DialDim Controller to the splash guard. Be sure there is enough clearance
for the seat to be re-installed.
2.2 - Positioning The Controller
1. Harness Overview
1.1 - Overview of Harness
2.1 - Locating the Battery
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2. Installing The DialDim Controller
Right Turn
Pass-Through
Horn
Pass-Through
Left Turn
Pass-Through
Headlight
Pass-Through
Output to
DialDim Controller
Battery
(Under Left Side Cover)
DialDim Controller
(Under Seat)

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The KLR650 DialDim Harness will be connected in-line to the four following
factory harness connectors: Headlight, Right Turn Signal, Left Turn Signal
& Horn
Step One: To gain access to the connectors, remove the left and right
hand side fairings. There are six bolts on the outside, and three plastic
screws on the inside edge of each fairing.
Step Two: The headlight connector of the KLR650 is located on the back
of the factory headlight housing, it is a black 6-pin connector. Disconnect
the factory headlight connector, then connect the “Headlight Pass-Through
Connector” of the DialDim Harness in-line.
Step Three: The right turn signal connector is located inside the upper
fairing, just behind the factory turn signal. It is a black 2-pin connector, you
will find it clipped onto a holding tab built into the fairing stay. Disconnect
the factory turn signal connector, then connect the “Right Turn
Pass-Through Connector” of the DialDim Harness in-line.
Step Four: The left turn signal connector is located inside the upper
fairing, just behind the factory turn signal. It is a grey 2-pin connector, you
will find it clipped onto a holding tab built into the fairing stay. Disconnect
the factory turn signal connector, then connect the “Left Turn Pass-Through
Connector” of the DialDim Harness in-line.
Step Five: The horn connector is located directly on the factory horn,
which is located on the lower right side of the motorcycle, along side the
coolant reservoir. Disconnect the factory horn connector with the RED wire
then, connect the “Horn Pass-Through Connector” of the DialDim Harness
in-line.
3.1 - Locating Connectors & Installing the Harness
3. Installing The DialDim Harness
OEM Headlight
Connector
OEM Horn
Connector
OEM Left Turn
Signal Connector
OEM Right Turn
Signal Connector
Battery
DialDim
Controller