Electric Probs - 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 23 Old 08-11-2009, 12:24 AM Thread Starter
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Join Date: May 2008
Location: Nanaimo, BC, CANADA
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Electric Probs - headlight ...

so last ride, my headlight stopped working and my powersocket stops working, heated grips are off after 600km of riding. plug and grips are wired to the brown w/ white wire under front cluster. No high or low beam or running tail light with ignition on. replaced fuses to be sure. no help. checked connections and grounds and found nothing. weird part ... if i put the ignition back to the park postion, i get power to my socket, grips and tail light so i know that circuit is good. brake lights work in the on position. are there more fuses? or just 3? could a blown head light interrupt the whole circuit? i have a clymer only showing 3 fuses. any thoughts? thx. i'll be pulling it apart tomorrow.

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks

Last edited by doc3toes; 08-12-2009 at 02:05 PM.
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post #2 of 23 Old 08-12-2009, 02:06 PM Thread Starter
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Location: Nanaimo, BC, CANADA
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head light bulb is good but no power going to it. checked alll connections and fuses again, all ok. Could this be my ignition switch. i havent check the hi/low switch yet, that is next.

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks
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post #3 of 23 Old 08-12-2009, 06:52 PM Thread Starter
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Location: Nanaimo, BC, CANADA
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FYI - turned out to be the ignition switch. blasted some cleaner in there. good as gold.

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks
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post #4 of 23 Old 10-05-2009, 12:02 AM Thread Starter
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Location: Nanaimo, BC, CANADA
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ok its screwed again after 2 months without a problem. exact same as before. if you can believe it ... supposed to go on a bike trip tomorrow. have to take my wife's klr instead. switch seems ok when i took it apart ...

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks
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post #5 of 23 Old 10-05-2009, 10:21 AM
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Location: Benicia, CA
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You been doing a good job helping yourself. I wish I had any ideas for you, brother. Good luck. Maybe someone will chime in?




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #6 of 23 Old 10-19-2009, 03:13 PM Thread Starter
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bike trip was good. my bike is torn apart in the garage, so i hope to report back this week on what i find. going to swap parts from my wife's bike to mine until i get an answer. im sure it is in the clutch switch or the ignition switch some where. the continuity in the ignition seemed ok, but maybe not making the contact properly when the key is turned. clymer is no help on this.

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks
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post #7 of 23 Old 10-23-2009, 10:58 PM Thread Starter
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Location: Nanaimo, BC, CANADA
Posts: 269
need spark help, i'm stumped.

ball sack. swapped out the ignition switch from my wife's bike. no help. so much for theory #1. start/kill switch looks ok. clutch switch looks ok. haven't had a look at the kickstand switch yet.
anyone?with key to on; no head light, no acc power, no tail. with key in park, i get tail and accessory power, and head light icheck good. n light always good, fuses good, starts and runs. battery fully charged, no rundown. female harness from ignition switch to where?
what about the coil and stator?

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks
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post #8 of 23 Old 10-23-2009, 11:04 PM
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Can someone please help this man!




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #9 of 23 Old 10-23-2009, 11:16 PM
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Could be loose contacts in the connectors. Wiggle some connectors to see if you lose power. Pack some dielectric grease in all connectors.

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #10 of 23 Old 10-24-2009, 04:23 PM Thread Starter
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man i just can't get this. checked all connectors today. re checked the bulb. here is a question (now that i can't find my clymer) there are 3 wires going to the light: black with yellow stripe, red with yellow stripe and red with black stripe and brown dot. Now i can follow the black/yellow to the connector (in the pic it comes to the bottom of the connector in the back and one in from the right) and test the continuity to the light is good, switch on or off) but the red/black/brown wire i dont get any continuity on from the light plug. my question is ... should i? the red/black/ brown also goes into the plug in the back of photo 2, just looks like a splice? both pics under the tank on the right side, just behind the rad.

also a few more checks: with ignition on, i get N light, turn signals, horn, starter,
I don't get : accessory power (brown and black under the farring - power for grips, and socket), headlight or tail light.

with ignition to park i get: all the above plus tail light and accessory
i don't get headlight (ever), no guage lights either

hi/low beam no diff.
starts fine
battery good

Thanks, i hate going to the stealership, but i might just have to pack it in on this one.
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02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
96 zx11 - bone stock - saving for a collector plate
2011 BMW f800 GS - [email protected] crash bars, altrider skid plate, barkbusters, kako, aeroflow med, heated corbin, wolfman, kenda big blocks

Last edited by doc3toes; 10-24-2009 at 04:38 PM.
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