Headlight Failure - 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 18 Old 11-21-2017, 10:25 PM Thread Starter
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Headlight Failure

Hello,

I'm new to the KLR world, I recently picked up a 1999, and i've been really enjoying it. it runs great, but a few days ago the headlight stop working. So, tonight I got around to investigating. I haven't done much maintaining lately, so I began by trying to install a new bulb, I was skeptical that that this would work, because the bulb inside looked rather new, anyways I got it out, and it was clearly not blown. I proceeded to rip apart the electrical wire and the switch that is installed on the bike that is supposed to switch from high to low, thinking the swtich might be faulty. Finally I realized I was being crazy, and I should check for a fuse box!

Upon searching the internet, the first thing I read in the first two seconds, is that if you leave the switch in the middle position you will blow a fuse!

So now I pull the seat off and look for the fuse box, wait theres not fuse box, oh the diagram shows one 10A fuse, but where is it!

Also, now that I have the switch and three wire disconnected from the switch, isnt that equivalent to having the switch in the middle position? am I about to start frying things!?

anyone know where I can find this fuse? and/or if shouldn't touch the bike without the wires connected to the switch?

thank you
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post #2 of 18 Old 11-22-2017, 03:59 AM
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I think the following link reveals a KLR650 wiring diagram appropriate for your vintage:

https://www.google.com/search?q=klr+...mL16CUIBlnZ2M:

(If the link doesn't work, Google: "KLR650 Wiring Diagram.")

This tool and a multimeter should answer your questions.

Recommend replacement of the existing 10-amp headlight fuse with a 15-amp fuse, reducing the chance of blowing the fuse when Hi-Low switch illuminates both filaments simultaneously.

Last edited by Damocles; 11-22-2017 at 04:11 AM.
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post #3 of 18 Old 11-22-2017, 09:55 AM
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Yep; fuse is under the seat above the airbox in a little black looking "pill box".....there should be a spare there too but I use a 15 amp as Damocles mentioned. ....and you won't fry anything unless you start to short wires and even then, that's what the fuse is for.

Dave
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post #4 of 18 Old 11-22-2017, 12:50 PM Thread Starter
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thankls for the reply, i found the fuse and its blown, but now im wondering what happened to my turn signals.. i removed the front fairing and when i went to plug the signals back in, the right side operated normally, but when i hit the left signal, the rear left comes on solid, doesnt blink, and the front left doesnt light up at all. i checked the wiring diagram, the left is plugged in just as it says, black/yellow - blk/yllw and the green to grey.. what gives? any ideas?
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post #5 of 18 Old 11-22-2017, 01:57 PM
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I'll suggest the possibility of the left front bulb being burned out. Or socket corroded?
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #6 of 18 Old 11-22-2017, 06:56 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
I'll suggest the possibility of the left front bulb being burned out. Or socket corroded?
yea, i took the front plastic orange shield off and try to pull the bulb out, it didnt come out, is this the proper way out? not sure, but there was a lot of corrosion going on down there, the act of trying to pry it out must have cleared out some crud, because it started working again!

everything is operational now, except the high beam, when i flip the switch to high, the light just turns off, dunno what this is about.
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post #7 of 18 Old 11-22-2017, 07:44 PM
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High beam filament burnt out, inspite of "looking near new"? It happens!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 18 Old 11-22-2017, 08:09 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
High beam filament burnt out, inspite of "looking near new"? It happens!
i just installed a new bulb tho
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post #9 of 18 Old 11-22-2017, 08:27 PM
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See if you get + 12 VDC on the high beam contact at the headlight bulb socket (understand low beam works o.k.). If not, Hi/Lo switch and/or wiring is compromised.

If you get + 12 VDC on the high beam contact when appropriately switched, and still no illumination, then . . . pdwestman's postulation (burnt-out high beam filament) may be the problem.
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post #10 of 18 Old 11-23-2017, 11:22 AM Thread Starter
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omg do these things just shit the bed when you start messing with them?? i got everything back together last night, even let it run for awhile ( it has always started, every time ive started it ) went to bed, woke up, all ready to ride.. wont start.. turns over hard like normal and then dies after a few seconds!

geez. what now ? any secrets i should know about? seems like an air or fuel issue, its just starving out
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