Denali KLR650 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 gear
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 forks, 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,
nuts, 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 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?
DENALIELECTRONICS.COM
Switched Power Adapter
Kawasaki KLR650
DNL.WHS.22300
Instruction Manual
(a) Wiring Adapter....................................................................Qty 1
(b) Relay.................................................................................Qty 1
Kit Contents
(a) (b)

1. Accessory Power Activation
1.1 - Installing The Relay
To activate the factory accessory power, the relay must be installed into its socket on
the KLR650’s factory wiring harness.
Note: If your KLR650 is already equipped with the factory LED auxiliary light set, grip
heater set, or USB socket kit then a relay will be pre-installed from the factory. If your
KLR has the factory relay installed, skip to Section Two.
Step One: Remove the right side fairing to gain access to the relay socket. The relay
socket is mounted on the vertical fairing brace.
Step Two: Install the relay into the socket.
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2.1 - Connecting The Wiring Adapter
Step One: Remove the left side fairing to gain access to the USB socket connector.
Note: If your KLR has a USB port, it will be connected to the port. If your KLR does not
have a USB port, you will find the connector attached to the vertical fairing brace.
Step Two: Plug the wiring adapter into the USB connector. If your KLR has a USB port,
plug the other end of the adapter back into the USB port. If your KLR does not have a
USB port, re-attached the connector to the fairing brace.
1. Installing The Wiring Adapter
2.2 - Connecting Accessories
This switched power adapter is intended to send a 12V trigger signal to relayed wiring
harnesses and low power (<2A) accessories only. High power (>2A) accessories
should NOT be connected directly to the adapter. Powering high power accessories
directly from this adapter could overload the circuit and blow the factory fuse.
Step One: Connect the positive lead of your harness or accessory to the white 12V
positive wire using the pre-installed posi-lock connector.
Step Two: If applicable, connect the negative lead of your harness or accessory to
the black 12V negatived wire using the pre-installed posi-lock connector.
12V Positive (+)
From Main Harness Wiring Adapter
Relay
Relay Socket
To USB Port
12V Negative (-)