Help, 09 died, electrical? - Kawasaki KLR 650 Forum
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post #1 of 34 Old 09-10-2011, 01:35 PM Thread Starter
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Help, 09 died Again, electrical?

I have lost the entire electrical system.
I was getting ready to leave for a ride and bike was running in Neutral.
I needed to grab a part so I dropped the side stand and got off.
Bike fell over running then quit, entire electrical is dead.
I checked the fuses I could reach, starter main I could not easily get to but that should not affect the entire system I hope. I don't even have lights now, any ideas where I should be looking?
I checked the kill switch and it does not appear damaged.
Same for the stand switch, it should not kill everything?
What would kill the entire system?

Help Needed ??????

Last edited by Stinker; 09-13-2011 at 05:04 AM.
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post #2 of 34 Old 09-10-2011, 01:43 PM
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First place I'd go is to the battery terminals. Try remove and re-install. When the bike took the spill, the ground may of been lost, which may be why it died. The Gen II needs a battery to run. The Gen I bike will run without a battery in it.

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post #3 of 34 Old 09-10-2011, 02:20 PM Thread Starter
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Thanks for the quick reply.
It was the Main that blew.
After some thought and reading the
manual I found out that the starter fuze was
actually the Main Fuse for the entire system
and I had better start there.
I did and it was a bitch to get to. I ended up
having to remove the relay mount to access
both sides of the fuse cover clips.
Now I am off to the store to replace the spare
20amp fuse.
This glitch killed my ride for the day but at least
my bike is alive again.
Thanks<<>><
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post #4 of 34 Old 09-10-2011, 07:08 PM
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Quote:
Originally Posted by Stinker View Post
Thanks for the quick reply.
It was the Main that blew.
After some thought and reading the
manual I found out that the starter fuze was
actually the Main Fuse for the entire system
and I had better start there.
I did and it was a bitch to get to. I ended up
having to remove the relay mount to access
both sides of the fuse cover clips.
Now I am off to the store to replace the spare
20amp fuse.
This glitch killed my ride for the day but at least
my bike is alive again.
Thanks<<>><

The question you should be asking is why the fuse blew when the bike fell over. The wiring harness is a likely suspect.

The gen 2 bikes had a recall on the wiring harness. A common place for a short is where the harness passes over the voltage regulator (black finned thing right side behind the radiator overflow tank). The edge of the gas tank pinches the harness against the regulator.

I had a short in that area when I put on the brakes, never did find a burned spot but I re-routed a bit and added some extra spiral wrap and padding in the area.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 09-12-2011 at 12:28 PM.
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post #5 of 34 Old 09-10-2011, 07:43 PM Thread Starter
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Mine has had the recall taken care of I'm told (hope), is there any way to know for sure!

Last edited by Stinker; 09-10-2011 at 07:45 PM.
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post #6 of 34 Old 09-12-2011, 09:33 PM Thread Starter
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Spec
how did you know, you must have a crystal ball.
All was rosey until I got on the freway and a mile down the road. Yep dead again, now I get to chase a short. anyway to know if I had the upgrade done for sure, is the harness marked? Kaw says no recalls on my bike, dealer said it was done, but have also been told other work was done (not!)!
what is the best procedure and locations for chasing this short?
Thanks
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post #7 of 34 Old 09-12-2011, 11:12 PM
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Quote:
Originally Posted by Stinker View Post
Spec
how did you know, you must have a crystal ball.
All was rosey until I got on the freway and a mile down the road. Yep dead again, now I get to chase a short. anyway to know if I had the upgrade done for sure, is the harness marked? Kaw says no recalls on my bike, dealer said it was done, but have also been told other work was done (not!)!
what is the best procedure and locations for chasing this short?
Thanks

Bummer.

Take off the seat and tank. Check how the harness is routed, look for any obvious burn spots. Problem area #1 is above the voltage regulator. I never did see any burns there but it was getting pinched pretty bad by the tank. I added some spiral wrap and padded the edge of the tank and have been good ever since. Another area is right by the battery where the cables go under the tank.

The recall didn't replace the harness just routed it better and added some insulation in trouble spots.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #8 of 34 Old 09-12-2011, 11:56 PM
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Did you just get this bike?? and its an 09?? Get ready for some fun

I had quite a lot of electrical gremlins with mine, especially in the rain. Damn thing would die all the time. Recall had been done.

When you get a free weekend you might want to consider tearing the bike apart and giving it a good look. Its a good way to learn about the bike so that you can fix it on the road if you have problems in the future

Erik
2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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post #9 of 34 Old 09-13-2011, 02:44 AM Thread Starter
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Electric, Dead Again ?

Bought new in 09 and this is the 1st. real glitch.
And trick to chasing the short with a ohm meter
when the main is toast and there are no obvious
burns/cut/pinched wires ?
O well I will at least be able to install a 12v plug when the tank is off.

Spec were you popping your main, did you run a jumper when you installed the
new wrap?

Last edited by Stinker; 09-13-2011 at 05:03 AM.
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post #10 of 34 Old 09-13-2011, 09:23 AM
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Also check behind the instrument panel. I had a couple rub spots back there with exposed wires.

Erik
2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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