Replaced fuses with Circuit Breakers - 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 12 Old 06-02-2007, 07:44 PM Thread Starter
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Replaced fuses with Circuit Breakers

Followed the instructions on this site today http://www.geocities.com/MotorCity/D...4/page122.html
and upgraded from the awful glass fuses to circuit breakers. Used a 15 amp and 20 amp. Now if a problem occurs such as the headlight getting caught between hi and lo beam and blowing a fuse, the extra 5 amps should cure that, and if it doesn't and it still trips the breaker, all I will have to do is turn the key off and then back on and the breaker will reset. No more removing the seat to replace fuses. I didn't do the fan fuse yet. Waiting till I find a good water proof switch to mount to reset the breaker with if it gets tripped.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #2 of 12 Old 06-02-2007, 11:50 PM
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Now there's a good idea worth following up on. I have lost both fuses before,thou not at the same time.Fortunately lost the headlight in daylight hours and the fan fuse on a group ride in the mountains.Didn't take long to replace,but held up the group for a couple of minutes.i think I will do the circuit breaker mod. If ya see any problems,let us know.


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post #3 of 12 Old 06-03-2007, 10:15 AM Thread Starter
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Will keep you posted, I also used the heat shrinkable connectors to connect the inline fuse holders. You can find these at any car parts store or a marine store. Keeps all connections nice and waterproof. You also keep the factory connections in the wiring harness, making it easy to replace if necessary.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #4 of 12 Old 06-29-2007, 05:35 PM
 
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I blew my headlight fuse this morning, in the dark, and rain, with lots of deer around. Interesting situation. It is the second time it has happened! The Kawasaki support guy said that he has never heard of this happening with the KLR. What gives?
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post #5 of 12 Old 06-29-2007, 08:02 PM Thread Starter
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I have heard the switch can sometimes hang up between low and hi beam putting more strain on the lil 10 amp fuse, thus causing it to blow. Either up grade to a 15 or, change the fuse to a breaker, much easier to turn the key off to reset than to pull the side covers and seat to change a fuse.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #6 of 12 Old 06-29-2007, 11:27 PM
 
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Thanks for the scoop. I did replace the fuse with a 15 amp. I was able to cruise into a gas station without getting smoked in the dark. The tool kit came in handy. The kawasaki folks told me to schedule an appointment at the shop to look for a short. I guess I'll see what they say. I do like your breaker option.
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post #7 of 12 Old 06-30-2007, 01:42 PM Thread Starter
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Quote:
Originally Posted by fireboykirk View Post
Thanks for the scoop. I did replace the fuse with a 15 amp. I was able to cruise into a gas station without getting smoked in the dark. The tool kit came in handy. The kawasaki folks told me to schedule an appointment at the shop to look for a short. I guess I'll see what they say. I do like your breaker option.
Here's the link to for the instruction on doing the breakers.
http://www.geocities.com/MotorCity/D...4/page122.html

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #8 of 12 Old 07-01-2007, 01:08 PM
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Quote:
Originally Posted by fireboykirk View Post
I blew my headlight fuse this morning, in the dark, and rain, with lots of deer around. Interesting situation. It is the second time it has happened! The Kawasaki support guy said that he has never heard of this happening with the KLR. What gives?
All it takes is about 10 seconds of having the hi/low beam switch stuck in the middle. Both beams try to light, and it blows the fuse. I did it for the first time a couple weeks ago, and I've put 15,000 miles on the bike. We were just about to head out for a ride and a buddy pointed at my headlight. Light was out, and the switch was in between hi and low beam..

I pulled out the fuse, stuck in the spare, and off we went. Gonna look into the breaker, though.
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post #9 of 12 Old 07-01-2007, 01:14 PM
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Says page is unavailable when I try to pull it up. Would like to read up on this upgrade. Please repost site/link if possible.

Thanks
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post #10 of 12 Old 07-01-2007, 06:18 PM Thread Starter
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Quote:
Originally Posted by haus View Post
Says page is unavailable when I try to pull it up. Would like to read up on this upgrade. Please repost site/link if possible.

Thanks
I'll get the complete link, or just try to copy and paste if that is not a problem in here?

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote
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