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Old 06-28-2015, 11:40 AM   #1
slepe67 OP
Gnarly Adventurer
Joined: Jul 2006
Location: Northwest Montana
Oddometer: 102
Tidying up Dual Sport Headlight Area. Got pics?

Hey, Im finally on the final push to having my Baja Designs D.S. setup completed on my '95 XR600R. Some of it is old, some of it is brand new (headlight/numberplate).

The rat nest of wiring behind my number plate is bringing out my OCD.

Before I zip tie everything together, Im just wondering if anyone is proud of their setup & would like to share pics.

Thanks in advance!
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Old 06-28-2015, 04:41 PM   #2
Green Chile Eater
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Joined: Apr 2009
Location: Out in the NM Dez somewhere
Oddometer: 6,472
Not especially proud of this one but it did the job for 3 years.

"Life's journey is not to arrive at the grave safely in a well preserved body, but to rather skid in sideways, totally worn out, shouting ... Holy Shit, what a ride!"
CL Adventure Ride 2013 /CL Revisited 2014 / 700 Miles of Scenic Utah Backcountry / MY VIDEOS / RIDEFREAK TV
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Old 06-28-2015, 04:50 PM   #3
Sinbad on wheels
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Joined: Jan 2009
Location: Westminster, CA
Oddometer: 37
^^^ That's actually pretty good. You ought to see the cluster fuq the p/o did on my XR400 while installing the Baja Designs kit. It isn't THAT bad, I suppose, but you can tell they didn't put all that much thought into routing everything nicely. They even routed the decomp cable over everything else and it had almost zero freeplay. When you'd turn the bars to the left it'd actuate the decomp even when adjusted all the way out. Rerouted the cable properly and moved the other locknut to the other side of the bracket and it's pretty good now. Just a friendly reminder to double-check your adjustments when you buy a used bike. Even my clutch had too much freeplay to where I believe it was dragging; it now shifts much smoother since properly adjusting it.
Truckers make the world go 'round!
CA plated '02 XR400R
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Old 06-28-2015, 06:15 PM   #4
Trans-Global Chook Chaser
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Joined: May 2004
Location: Rotoiti, New Zealand
Oddometer: 3,584
Have a look at my headlight mods here

No decent pics of the wiring unfortunately but what I did was remove any redundant wiring, replace the 3 loose relays in there with 3 micro relays ganged up in joined mounting blocks & bolted on a plate next to the dash, a couple of diodes & fuses mounted on there too, also mounted up the 3 wiring connectors through a bracket under the dash.

I have seen some nice setups using some new waterproof Deutsch connectors sized for just the number of wires needed & ziptied on to a bracket behind the headlight.

'03 KTM 640 LC4 Enduro

The wilderness, the desert - why are they not crowded
.................................................. .....with pilgrims?
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Old 07-01-2015, 10:42 AM   #5
slepe67 OP
Gnarly Adventurer
Joined: Jul 2006
Location: Northwest Montana
Oddometer: 102
RideNut, that is CLEAN! I ma6 be hardpressed to get mine to look that good, but I'll give it a shot!

Thanks everyone, especially for he links
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