'07 Electrical Short - FIXED - 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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  • 1 Post By Uncle Dick
  • 1 Post By Damocles
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post #1 of 6 Old 05-17-2020, 01:23 PM Thread Starter
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Join Date: Apr 2020
Location: CO
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'07 Electrical Short - FIXED

In the middle of a long ride yesterday I notice my tachometer wasn't reading and my blinkers weren't working. I was able to ride another hour to my buddies house but wasn't able to get the electrics working. I took the seat off and found the main fuse was blown.....I replaced it and it kept blowing.....electrical short!!

Luckily, I was able to coast down his driveway, pop the clutch, get her started and drive home before dark. This morning I stripped it down and found one of the horn connectors was rubbing against the frame and causing a short. I yanked the horned, taped up the wires and it started right up.

I thought I'd post here in case anyone had questions with shorts or disassembly/reassembly and I can share my experiences. It was fairly easy and I had it working and back together before noon.

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post #2 of 6 Old 05-17-2020, 02:02 PM
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Greetings spinach, you’re one lucky or very smart fellow to have found the cause of the short so quickly. Good for you, and by the way, welcome.

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post #3 of 6 Old 05-17-2020, 02:46 PM Thread Starter
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Thanks, Dick!

Trust me, most likely the former ....I tried to include pics and a video but the forum stripped it w/o me at least 15 posts...

https : // www . youtube . com/watch?v=ee5wfxfjeUg

https : / /imgur . com/Hh0cm9o
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post #4 of 6 Old 05-17-2020, 10:10 PM
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“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #5 of 6 Old 05-18-2020, 06:47 AM Thread Starter
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Thanks, Dam!
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post #6 of 6 Old 05-18-2020, 11:08 AM
Join Date: Nov 2009
Location: Lander, Wyoming
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For others, for future diagnostics.

One can use a headlight bulb with both HI & Low terminals jumper wired to battery side of fuse terminal and ground side of bulb jumper wired to ignition switch side of fuse terminal to act as a NO BLOW fuse. Disconnect the bikes headlight.

The NO BLOW will glow dimly with normal current & glow full 10 amps brightly as short is contacting, but it will not burn out.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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electrical, fuse, gen 1, klr650

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