Electrical problems - 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 5 Old 06-11-2007, 09:00 AM Thread Starter
2nd Gear
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Join Date: Oct 2006
Location: Klamath Falls, OR
Posts: 440
Electrical problems

While coming home from a long weekend I noticed that my temp gauge went to cold and my tack was bouncing from 0 to 4000 RPMs. Also my battery monitor was showing that the battery was de-charging. When I pulled over my blinker, light just flickered and the Natural light was dim. Checking the lights, found the taillights were on but very dim, hit the breaks and they would not work. Head light would work at low RPMs but would flicker at 4000 RPMs.
I decided to make a run for home, as it would be getting dark. When I took off the temp gauge and RPMs started working fine as did the head light and taillights. After another 8 to 10 miles, things started acting up again. I have an after market left side assemble for the lights and blinkers so I just turned the lights off.
Here are a few other details:
When I would turn on my heat grips, the RPMs would show the proper amount for the speed I was running. Same thing would happen when I would turn blinkers but the lights would just flicker. My GPS never showed that it went to its battery so it was running off of the motorcycles charging system.
When I got home I was able to start the bike several times with out any problems, lights however would still just flicker.
This morning though nothing, no lights and nothing when I hit the starter.
I will start pulling thing apart tonight, checking and cleaning all connections.
I have not added anything new to the bike in the last month.
So I said all that, to ask this: What or where is a good starting point to start looking?


KLR 650 - A18
2017 Honda Goldwing
Triumph Sprint ST - 2008 - Sold
Polaris Sports Man 300 4x4 - Wife's
Polaris Sports Man 400 HO 4x4
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post #2 of 5 Old 06-11-2007, 11:16 AM
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Location: Paso Robles, CA.
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It sounds like just a loose battery connection.
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post #3 of 5 Old 06-11-2007, 12:54 PM
3rd Gear
Join Date: Sep 2006
Location: Franklinville, NC
Posts: 650
Thanks for coming down over the weekend Craig !

And what a bummer way to get home.

The loose battery connection like SLO-klr says would be first check. while your there, pull it out and check the water level, and check voltage, maybe a charge will be in order too.
look for frayed wires and a loose ground under there. maybe pull the tank and check there too.
If the batterys dead and a connection was loose I'd say that was the whole prob. if not and you have doubts... your going to have to look deeper into the wiring.

- Joe

HighSpeed Hiker- DV o5'
Originally Posted by larryboy
come awn... it's not far...it'll be fun..

sorry I can't....... I'm fishing today
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post #4 of 5 Old 06-14-2007, 10:44 PM Thread Starter
2nd Gear
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Join Date: Oct 2006
Location: Klamath Falls, OR
Posts: 440
Well, I have torn the bike apart looking for this electrical problem. So far I have found nothing . The connections to the battery were tight and clean. However after removing and re-installing both battery cables she has not had a problem since. I literally took apart, checked and cleaned if necessary every electrical connection. Checked continuity, power and fuses then put things back together using Dielectric. The battery is a super battery and was showing 12.8 volts with 0 load.

I am trying to track down this problem before my 1600-mile trip, the weekend after next.

I figured since I had her all torn apart I would do a few other things. In addition to what I already listed, I did the following.
Checked the valves, right in the middle of spec.
Went up one size on my main jet, added a very very quite muffler that breaths a lot more air. So the bike was running a lot lean, 62.26 miles per gallon averaged over almost 1350 at 49 miles per hour.
Cleaned and re-oiled the air filter (K & N)
Cleaned the oil filter (K & P)
Lubed the clutch and speedo cable.
Re-locktight things as they went back on the bike.
So far I the bike is running great, I would hold my breath but I don't want to turn purple.
Will be keeping an eye on it, hopefully I will have no more problems.

KLR 650 - A18
2017 Honda Goldwing
Triumph Sprint ST - 2008 - Sold
Polaris Sports Man 300 4x4 - Wife's
Polaris Sports Man 400 HO 4x4
28 foot Travel Trailer
Not enough time to play
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post #5 of 5 Old 06-15-2007, 04:48 PM
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
There is nothing worse than electrical gremlins. A couple of weeks after I bought my bike, I noticed a few times when I hit the start button, I got a buzzing sound and then the neautral light and everything else would die. Turn the key off and would do it maybe one more time, then after a couple of taps of the starting button, the bike would fire up and go without a hitch. I finally took the battery out and did a full day charge on it and "crosses fingers" have not had any more issues. While I had all my body work and tank off last week doing my valves and subframe upgrade, I took the opportunity and put di-electric grease at all electrical connections and junctions. Your battery wires might be corroded down inside where you can't see. Have had same issue on cars and mowers. At any rate, I hope you have no more issues with it.

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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