headlight fuse - 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 2 Old 12-26-2011, 08:06 PM Thread Starter
1st Gear
Join Date: Nov 2008
Posts: 21
headlight fuse

I'm open to input on something I've run into. I've got an 08 that popped the headlight fuse just out the driveway the other night.The next day I replaced the fuse and everything worked until I started it. It cranked really slow and the fuse popped.Pulled battery and it was really low on acid so I filled her up and let her charge. Since I reinstalled the batter,I can't duplicate the problem. It starts fine with no blown fuse. Even though it had the wiring harness mod done 20,000 miles ago I still looked the wiring loom over. No elecrical accessories have been added and no previous problems. Since low voltage increases amps,could the weak original battery have caused the 15 amp fuse to blow?
I hope someone has run into a similar problem. Any input is welcome,thanks.
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post #2 of 2 Old 12-27-2011, 06:46 PM Thread Starter
1st Gear
Join Date: Nov 2008
Posts: 21
After a short test ride with new batterythe fuse blew. Decided to get serious and pulled all the plastic and the tank. Found a spot rubbed into the red wire coming from the 15 amp fuse just before it gets to the 9 wire connector under the tank. Even though the harness mod had been done,kawasaki doesn't take the effort to secure everything snug. Test rode it a couple of miles and all is good.
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