I've really done it now/ Ignition problem - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

  • 1 Post By Damocles
  • 2 Post By Tom Schmitz
  • 1 Post By dan filipi
  • 1 Post By JTCrow
  • 1 Post By planalp
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post #1 of 9 Old 12-29-2018, 12:27 AM Thread Starter
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Join Date: May 2017
Location: Concord, MA
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I've really done it now/ Ignition problem

MY gen 1's steering lock has never worked right. The key will turn to the left without having to push the key down and it only locks when on "park", it will not lock in "lock" position.

So today I finally decided to take a look at it. I took off the fairing and removed the two screws to the ignition. I did not remove the two snap-away bolts that have to be drilled out, but the two screws next to them that allows the ignition cylinder to be removed.

With the cylinder out I fiddled with the steering lock. There is a small plastic triangle shaped actuator that pushes on the pin and the pin pushes out and locks the steering. The tip of the triangle was only pushing out the pin in full "park" and not in "lock". I fiddled with it and positioned the actuator so that now it works, and it locks in park!

BUT...now when I turn the key to "on" I get not juice. Total let down! Unfortunately there is nothing at all about the ignition cylinder internals in fiche or pictures or videos or manuals or anything. Nobody else is stupid enough to take this apart knowing nothing about how it works? Just me?

Here is a picture.

I'm thinking maybe there is a spring or ball bearing in the ignition that went missing? When I didn't get juice I just gave up to look at it with fresh eyes tomorrow but I'm hoping maybe someone else has been in the ignition and can help me out.


Last edited by JTCrow; 12-29-2018 at 12:31 AM.
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post #2 of 9 Old 12-29-2018, 03:22 AM
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Wish I could help you with the mechanics; electrically, in the upper left of the wiring diagram accessible from the link below, you can see a matrix of the ignition switch logic, and a schematic of the switch wiring:


In your position, if I couldn't figure out the mechanical connections, I'd need outside help or a box full of toggle switches to hot-wire the bike.

Hope a knowledgeable forum inmate provides you some info you can USE. Good luck!
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post #3 of 9 Old 12-29-2018, 05:02 AM
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These are the bits that should be in there, though I can't guarantee the order is correct. Do you see anything you don't have?

Are you sure that you have the rectangular piece with the copper bumps facing the right way?
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post #4 of 9 Old 12-29-2018, 09:28 AM
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Check the main fuse?
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post #5 of 9 Old 12-29-2018, 10:07 AM Thread Starter
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Thanks Tom!

It figures if anyone would have a picture of the internals it would be you! It looks like I'm not missing anything and I do have the brass wafer bumps out.
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post #6 of 9 Old 12-29-2018, 10:10 AM Thread Starter
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Originally Posted by dan filipi View Post
Check the main fuse?
I haven't gone down to fiddle with it yet. I do plan on checking the fuse and I'm hoping that's it. I did notice last night, when I was going over the bike with a flashlight, that the ground wire that is on the right side of the bike, near the steering head, broke off. I just had the crash bars off so the wire must have fatigued and broke in the last day or two. I'm going to fix that, cross my fingers and check the fuse.

Thanks so much for the help, Dan. You guys are the best! Wish me luck. I'll post back with whatever the outcome is.
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post #7 of 9 Old 12-29-2018, 11:32 AM Thread Starter
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I fixed the ground wire and got into the fuses. I have the mini blade fuses on the bike. The lights fuse was obviously blown but the main and fan looked intact. I changed them out anyways. Then I put the ignition back together and tried the key. Eureka! Juice! I was really worried but it turned out to be an easy fix. And the handlebar lock works now! I came out ahead! That's pretty rare, I'm going to buy a lottery ticket today.

Thanks again fellas!
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post #8 of 9 Old 12-29-2018, 05:35 PM
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Right on! Glad to hear you got it worked out!
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post #9 of 9 Old 01-01-2019, 01:42 AM
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Originally Posted by JTCrow View Post
And the handlebar lock works now!
Fine, but . . . who'd steal a KLR?

I jest; congratulations on getting things sorted out.
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