Trouble shooting headlight - 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 6 Old 07-03-2009, 12:16 PM Thread Starter
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Join Date: Mar 2008
Location: Souderton, Pa
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Trouble shooting headlight

My low beam is out. High beam is fine. All other electrical lighting is fine. I took the bulb out and put a vom on it and it shows the bulb is good. Now the question is what is likely the problem? I don't know the KLR quarks as well as you guys. Is there a weak spot somewhere? What is the likely problem. It has been fine as far as I know up until now. It just went out.

Before I start tearing everything apart maybe there is a simple answer? (I hope)

thanks for the help

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm

Last edited by thumbs; 07-03-2009 at 12:22 PM.
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post #2 of 6 Old 07-13-2009, 11:18 PM
 
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I had the same problem with low beam not working on my 2000 KLR. After spending a couple hours tracing through the front wiring loom. I found that the solder joint on the high/low beam switch had broken loose.

You can easily check to see if this is your problem by removing the two phillip screws holding the handlebar control(High/low beam switch & horn button) Remove the three tiny screws holding a small metal bracket inside the control unit that holds the high/low beam switch. You can then inspect the soldered joins on the three wires going to this switch. If one has broken loose it can easily be soldered.

Good Luck
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post #3 of 6 Old 07-14-2009, 12:34 AM
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Quote:
Originally Posted by barstowblues View Post
I had the same problem with low beam not working on my 2000 KLR. After spending a couple hours tracing through the front wiring loom. I found that the solder joint on the high/low beam switch had broken loose.

You can easily check to see if this is your problem by removing the two phillip screws holding the handlebar control(High/low beam switch & horn button) Remove the three tiny screws holding a small metal bracket inside the control unit that holds the high/low beam switch. You can then inspect the soldered joins on the three wires going to this switch. If one has broken loose it can easily be soldered.

Good Luck
Seen the same thing at a Tech Day in Elk Grove. Touched it with a soldering iron and all was well.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #4 of 6 Old 07-14-2009, 09:11 PM Thread Starter
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Join Date: Mar 2008
Location: Souderton, Pa
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Thanks guys. That was my next place to go. Can't get to it till next week but I'll bet thats it.

thanks again I'll let ya know how I make out.

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm
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post #5 of 6 Old 07-15-2009, 05:57 PM
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Gosh, Thumbs. When I read the title of your post, I though maybe you weren't leading it enough........
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post #6 of 6 Old 07-15-2009, 06:04 PM Thread Starter
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Location: Souderton, Pa
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very good, I get it. LOL

anyway hope it's in the switch.

Gary
Souderton, Pa.
89 xt350 wish I still had her
05 Suzuki DRZ 400
92 K75s
07 KLR 650
13 Triumph Storm
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