09 KLR smoked wiring - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 11 Old 09-26-2011, 11:00 PM Thread Starter
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Unhappy 09 KLR smoked wiring

Had an issue with my turn signal this morning, it worked intermitently then on the way I got smoke from the below the gage cluster. When this happened it shut down the bike and nothing works now. Has any one ever had something similar to this, and how are difficult is the wiring on these things. Good with the mechanical side not much on the electrical.
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post #2 of 11 Old 09-27-2011, 03:02 PM
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There are several areas on the 2008 and 2009 model year where the wiring harness rubs at different points. Check this forum and the others for pictures of where the rub spots are. They are easily corrected. Also, in your case, you may have blown the main fuse and thats why you have nothing. I cant remember under what heading you will find the electrical stuff, but Im sure another member will chime in.

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post #3 of 11 Old 09-27-2011, 07:43 PM Thread Starter
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Thanks I will check the wiring closer. I did find the blinker relay smoked, but would that shut down the bike? No fuses blown.
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post #4 of 11 Old 09-28-2011, 08:22 AM
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There are 3 fuses. Two 15 amp and one 20 amp. 20 amp is the main fuse and if it is blown, you have nothing. Just making sure you checked the main fuse. If it is still good and the other 2 are good, go back to the battery. Check to see if the battery is still good; if you have a solid ground off the battery etc. If all is good in these areas, then I am lost as to what should be checked/done next.

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post #5 of 11 Old 09-28-2011, 09:17 AM
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Quote:
Originally Posted by thunderhorz1 View Post
Thanks I will check the wiring closer. I did find the blinker relay smoked, but would that shut down the bike? No fuses blown.

You should check to see if the wiring harness recal was done on your bike.

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 #6 of 11 Old 09-30-2011, 06:53 PM Thread Starter
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Angry

Ok, here is what I have done so far I replaced the blinker relay and nothing happens. Cant find any rub throughs on wiring that I can see. Do i need to pull the tank and if so do I need to drain it? Battery is putting out 12.77 volts. Fuses are all good nuthing broke on the inside of them.

Any other ideas???????????????
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post #7 of 11 Old 09-30-2011, 07:16 PM
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You dont have to empty the tank to pull it but it makes it much lighter if empty or close to empty. I have pulled the tank several times and do it with whatever fuel is in the tank. Just checking....if you turn on the ignition do you have headlights? You can have a full battery but a poor ground and nothing will work. Have you checked the ground wire from the battery to the frame. As to the fuses, sometimes you think the fuse looks good visually but it is bad. I aways use a continuity tester to verify the fuse is good.

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post #8 of 11 Old 10-01-2011, 09:50 PM
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My 09 died totally and then realized it was only when the bars were turned. Ended up being a broken ground wire in the harness right below the ignition. They dont leave a lot of play in that harness. May be something to check. It wasn't very apparent as the wire was broke inside of its plastic jacket so you really have to play with it.
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post #9 of 11 Old 10-04-2011, 05:35 PM
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The main fuse is on the left behind a cosmetic cover. It is apart from the others. Have you checked this fuse?
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post #10 of 11 Old 10-05-2011, 09:24 AM
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after reading this thread and others i pulled my bike apart and went over the hole harness , my bikes only done 2000 miles and its rubbed in afew places , ive re rapped and in places put flexy plastic cover on the harness to sort it out, so with luck, no probs .
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