wiring prob (i think) - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 21 Old 08-01-2013, 11:38 AM Thread Starter
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wiring prob (i think)

OK. I turn the key light comes on. I press ignition light goes off no power. Thoughts/advice?
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post #2 of 21 Old 08-01-2013, 11:54 AM
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I recall that you had this same problem a month or so ago, no?

Damocles pretty well covered the bases on what could be wrong.

I might add that your battery may be weak, but even at that it should grunt a bit or the relay should make some racket.

Can you go back over what Damocles suggested and eliminate all of those items?

For starters, I would make sure that the battery is fully charged and disable the safety switches so that they don't get in the way of finding the problem.

T

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post #3 of 21 Old 08-01-2013, 12:12 PM
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Further thoughts -

When you press the starter switch, the headlight dims/goes out. That would indicate there is a large current draw somewhere. The fact that the headlight works would indicate no fuses are blown, so there's probably no short in the harness.

Just to be safe, check that main fuse to see if it's blown again.

It would seem to indicate a weak battery. Can you push start the bike?

T

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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post #4 of 21 Old 08-01-2013, 12:26 PM Thread Starter
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It was the same problem as a while ago. Just got back to it as I've been busy. I am hesitant to start messing with the wires but I cleaned and tightened the connection going to the fuse box from the battery and the problem has cleared up. Now though after I tried to start the bike the positive battery terminal was very hot. Is that normal. I have the battery on a charger I hope that's OK.
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post #5 of 21 Old 08-01-2013, 12:45 PM
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You should be using a small charger, one designed for motorcycle batteries, not car batteries.

A hot terminal (or anything) indicates a large current. It's not normal and indicates a poor connection, either due to it being loose or corroded. It could also be an internal fault in the battery. How old is the battery?

While you're diagnosing this, unplug the headlight. It's a heavy current draw and isn't helping matters, especially if the battery is weak.

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #6 of 21 Old 08-01-2013, 12:49 PM Thread Starter
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The terminal was hot after attempting to start the bike several times. I have power but it won't kick over. I now have it on a small charger charging at 6 amps and the terminal is cool to the touch. The battery came with the bike but I was told it was 6 months old and had been on a trickle charge.
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post #7 of 21 Old 08-01-2013, 12:53 PM
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OK, you definitely have a large current draw somewhere (likely the normal large draw of the starter motor). If the 20A fuse is not blown, then the draw is less than 20 amps.

If the battery can't deliver 20 amps, it's weak.

A 2003/Gen1 bike can be push started even with a dead battery. Recommend you try and push start the thing and see what happens.

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #8 of 21 Old 08-01-2013, 01:03 PM Thread Starter
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When you say normal large draw off the starter motor are you saying that's normal and should be expected? I am charging the battery and will buy a new one tomorrow if I can. Good battery recommendation?
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post #9 of 21 Old 08-01-2013, 01:06 PM
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Yes, it's normal for the starter motor to draw a large current. It's less than 20 amps, but nothing draws more. When you add the headlight to the starter, that's the most the battery will ever see, short of a dead short (pun intended). That's why I recommend that you disconnect the light while you sort out the electrical problems.

Off the top of my head I don't know what the starter draws, but the low beam on a Gen1 will draw 5 amps. That's 5 amps of draw you don't need right now.

The batteries that AutoZone sells are decent budget-type replacements.

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 08-01-2013 at 01:10 PM.
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post #10 of 21 Old 08-01-2013, 01:13 PM Thread Starter
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Thanks for all the help. I'm going to continue charging the battery for a couple hours and then give it a try. I'll probably buy a new battery even if it starts up. Then I'll ride off and on for a day to make sure before I take it fishing
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