Intermittent headlight and taillight failure - Help - 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 07-12-2009, 07:51 AM Thread Starter
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Intermittent headlight and taillight failure - Help

Both headlight and taillight fail, have had the fuse blow, changed it and all ok for about 20 minutes, then regular intermittent failure. Have now stripped the wiring loom and reworked all the connections, checked earth connection. still no lights.
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post #2 of 5 Old 07-12-2009, 09:52 PM
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Sounds like a fault to ground. Check your wire harness rubbing.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 5 Old 07-13-2009, 06:31 AM
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Well See my post my intresting day.. Kaw is replacing my wiring harness cause of the same issue only mine progressed to burn up the regulator and battery soon after the fuse blowing incident.
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post #4 of 5 Old 07-14-2009, 03:50 PM Thread Starter
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Thumbs up Thanks for the help, but.....

The info given not required, thanks though, started tracing the loom and found the fuse to be faulty, in that the glass tube, fuse link and end caps are merely slid together and not soldered....it was the fuse playing silly buggars with my common sence all the time...so as a warning, make sure your fuse is a good quality soldered type and not the glued slip together type....realy frustrating stripping the bikes loom to the bone just to find it was the 5 cent part all the while.........the joys of biking never end!!!!!!!
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post #5 of 5 Old 07-24-2009, 01:09 PM
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In the Navy electronic tech schools, they have an "Ace Breaker" lab problem for the really sharp techs. A real bugger to troubleshoot. But - I aced it.
The old "Shorted Fuse" problem. My old Senior Chief had already pulled that one on me before I attended that school. Bwahahaha!
Basically, the glass Buss fuse wire makes contact while cold - meters as fine. Then as it heats, it warps and opens - instant failure! But by the time the tech pulls it and tests it, it looks good again!

I converted all my KLR fuses to the plastic blade type - much more rugged!
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