2002 KLR650 15,000 miles, Electrical problem starting - Page 4 - 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 #31 of 35 Old 07-01-2019, 08:58 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
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I replied to everyone last week but I don’t see it anywhere on this thread? I found the problem and back on the road now! It was a hot wire in the start circuit arcing to the frame. Found it under the right side fairing. see the pictures attached. Thanks for the moral support and advice!
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Originally Posted by Tom Schmitz View Post
It seems you have a good battery.

What state of charge was indicated?

What you need to do now is begin to trace the wiring from the starter switch all the way through the starter circuit relay and on to the starter relay. Examine every wire near the connectors and the connectors themselves. Look for evidence of corrosion. Plug and unplug each connection to renew the connection. Test the starter circuit relay.
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post #32 of 35 Old 07-01-2019, 10:28 PM
Pretty in Pink, dunno why
 
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Join Date: Feb 2009
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Garage
I'm glad you found the problem!

Enjoy!

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #33 of 35 Old 07-02-2019, 08:48 PM
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Join Date: Nov 2009
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I hope that is the entire problem. But I'll try not to hold my breath.

A bared wire like that will usually blow a fuse, even a over Amped fuse. You might confirm that your bike has the proper sized fuses installed.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #34 of 35 Old 07-03-2019, 05:18 AM Thread Starter
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I was thinking the same thing and planned on looking at the wire diagram to see what size fuse and where the fuse should be.. Is it the one by the battery with the extra glass fuse on the side of it? That’s the only one I haven’t looked at yet. Hope I don’t find bubble gum wrapper in that fuse! I am a little worried that it caused other wires or contacts to get hot and melted.. I did find the start button spring got to hot and had to straighten the spring out. I’m hoping that spring was the weakest link in the circuit.

Quote:
Originally Posted by pdwestman View Post
I hope that is the entire problem. But I'll try not to hold my breath.

A bared wire like that will usually blow a fuse, even a over Amped fuse. You might confirm that your bike has the proper sized fuses installed.
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post #35 of 35 Old 07-03-2019, 11:23 AM
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Quote:
Originally Posted by Dennis Wallace View Post
I was thinking the same thing and planned on looking at the wire diagram to see what size fuse and where the fuse should be.. Is it the one by the battery with the extra glass fuse on the side of it? That’s the only one I haven’t looked at yet. Hope I don’t find bubble gum wrapper in that fuse! I am a little worried that it caused other wires or contacts to get hot and melted.. I did find the start button spring got to hot and had to straighten the spring out. I’m hoping that spring was the weakest link in the circuit.
2002 Gen 1 should have 2 fuses near the battery.

20 amp main fuse in the White to White circuit and 10 amp light fuse in the Brown to Blue/White circuit. (oem 2 fuse black plastic case in a rubber holder, on top of the battery)

I'm sure you noticed the 10 amp fan fuse near your issue area? (translucent plastic capsule)

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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