blowing fuses on my 09 - Kawasaki KLR 650 Forum
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post #1 of 8 Old 08-12-2012, 07:02 PM Thread Starter
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blowing fuses on my 09

I did the .22 cent mod the other day and went on a 150 mile trip yesterday and the bike died on me. I found the blown fuse and threw in the spare and it blew too. Then I remember that I had found the wires leading to the front brake unplugged the other day. I unpugged the two wires going to the front break, threw in another new fuse and it has worked fine since then. Any ideas, what do I need to do now?

J.B.
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post #2 of 8 Old 08-12-2012, 07:28 PM
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Could you be more specific about the wires you unplugged?

http://media.photobucket.com/image/2...0corrected.jpg

Off-hand, looks like a short-circuit, hot wire to ground; possibly from abraded harness wiring. Think the Generation 2 had a factory recall on that issue.
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post #3 of 8 Old 08-12-2012, 07:47 PM Thread Starter
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The two wires plug into the housing that the front break lever is mounted to. They were unplugged when I got the bike.

J.B.
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post #4 of 8 Old 08-12-2012, 10:07 PM
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Heh, they left it unplugged probably for that reason. Maybe its got a bad switch in there that activates the brake light.
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post #5 of 8 Old 08-13-2012, 04:58 AM
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Yeah, I'm with Ecip. If not the switch follow that circuit back till you find it.
You could take it to a dealer to see if the wiring recall has been done or DIY.

Harness Recall.pdf
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post #6 of 8 Old 08-14-2012, 07:20 PM Thread Starter
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Thanks Flash!

J.B.
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post #7 of 8 Old 08-14-2012, 09:11 PM
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so the dealer will check if the recall has been done and repair for free? i should get my 09 in and see about this.
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post #8 of 8 Old 08-14-2012, 09:29 PM
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Quote:
Originally Posted by Cottonmouth View Post
I did the .22 cent mod the other day and went on a 150 mile trip yesterday and the bike died on me. I found the blown fuse and threw in the spare and it blew too. Then I remember that I had found the wires leading to the front brake unplugged the other day. I unpugged the two wires going to the front break, threw in another new fuse and it has worked fine since then. Any ideas, what do I need to do now?

J.B.
My 08 did the same thing. What I found was that the wiring harness had a short right where it passed over the voltage regulator (black finned thing behind the radiator reservoir). The harness gets pinched between the tank and regulator. I rerouted a bit and put some hard insulation over the harness.

The recall doesn't replace the harness just reroutes and adds some insulation. Once you get the tank off it's not hard to locate the likely trouble spots. The regulator area is the number one place to check from the reports I've read.

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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