Signal lights prblem! Please Help its my daily driver! - 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 9 Old 08-15-2015, 09:05 AM Thread Starter
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Signal lights prblem! Please Help its my daily driver!

Hello guys,

Im new to the forum I just got my first KLR its an 06, Im 26.

So I am having issues with my Turn signals.

By Law in Costa Rica you must have working turning signals in order to renew your driving permit, you must go and have your bike checked every year to get this permit and i have my revision this october.

So here is the deal, I have 5W lights (not LED) on each signal, but they wont turn on.

I have followed the cables and i get power all the way to the signal switch, here is when something funny happens, i disassembled the switch and i checked for voltage and i get 11.5V on the orange cable, but as soon as I turn the switch to either right or left voltage drops to 0 and none of the lights will turn on at all.

Also I have checked and i dont have any power at the end connections but i do have power up to the switch.

What i dont understand is the voltage drop when I flick the switch to either right or left position, and why i dont get any power to the lights at all.

Any help is apprititated.

Thanks!
Andres
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post #2 of 9 Old 08-15-2015, 09:11 AM Thread Starter
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Also i forgot to metion al the other lights (break & headlight) work perfectly.
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post #3 of 9 Old 08-15-2015, 12:20 PM
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Your description makes it appear that the turn signal relay (blinker) has a very weak internal connection.

Try removing the relay and jumping between the brown wire and the orange wire. Then set the turn switch to right or left. If everything but the relay is good this shroud cause the signal lights to come on, but not blink because the relay is disconnected. If the signals work this way, the relay is bad.
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post #4 of 9 Old 08-15-2015, 01:29 PM Thread Starter
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Hey gomotor! thanks a lot that was it, the relay was burned out, thanks for your help!! Just wondering do you know why the voltage goes to 0? Is it because of it shorting out?
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post #5 of 9 Old 08-15-2015, 05:14 PM
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Quote:
Originally Posted by gomviandres View Post
Hey gomotor! thanks a lot that was it, the relay was burned out, thanks for your help!! Just wondering do you know why the voltage goes to 0? Is it because of it shorting out?
My guess is that the contacts in the relay are badly burnt and barely making contact (high resistance). When you move the switch to one side it connects the orange wire to ground through the signal bulbs elements and if the relay contacts have much more resistance than the bulbs, the voltage drop happens at the contacts.
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post #6 of 9 Old 08-15-2015, 06:03 PM
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The original relay/flasher unit will not work with those low (5) watt bulbs. I put some on an '06 and the lights would come on but not flash. The relay is designed to work with 23 watt bulbs.
I bought a cheap (so cheap that I got two, one as a spare) flasher unit from ebay and it plugged right in and worked just fine with the equally cheap indicators, also from ebay.
Complete change of all four indicators and flasher relay came to just under $10.



iddy
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post #7 of 9 Old 08-15-2015, 07:49 PM
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Bit of overkill, perhaps, but . . . an ELECTRONIC flasher likely will work with bulbs of any wattage, including LEDs.

Some parallel resistors probably would make the flasher work with 5-watt bulbs, but . . . as a solution to the problem, that scheme would be like using a rubber glove for a leaky fountain pen.

BTW, also in Costa Rica, ATVs are street-legal if they have horns and turn signals . . .
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post #8 of 9 Old 08-15-2015, 08:40 PM Thread Starter
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Yup I did that, I went to the shop and got an electronic relay and now everything works fine.

Yes I have an atv and all you need is high/low beam light, horn and turn lights and you are good to go anywhere.
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post #9 of 9 Old 08-16-2015, 01:25 PM Thread Starter
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Normk thanks for those files, you just saved me a ton of googling, they will be my go to source for troubleshooting from now on! No more Google screenshots!
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