Gen 2 Safety Switch Bypass - Page 5 - 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 #41 of 62 Old 09-18-2019, 05:54 PM Thread Starter
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Quote:
Originally Posted by Klrover View Post
...Tried the jumper method on my gen2 and still no joy...
What jumper method? The side stand switch? The clutch switch? Both?

Both switches must be activated to provide a path to ground for the starter circuit relay's coil. You should bypass them both.

If you have bypassed them both, then there is a bad ground path, either in the BL/R wire going from the relay and diode matrix to the clutch switch, the Gr/W wire going from the clutch switch to the kickstand switch, The LG wire going from the diode matrix to the neutral switch, or the Gr/Y wire going from the side stand switch to ground. Check them for continuity.

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Last edited by Tom Schmitz; 09-18-2019 at 05:57 PM.
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post #42 of 62 Old 09-18-2019, 05:58 PM
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Thanks Tom. I had assumed it was the clutch switch, but I understand you that they are both completing the same circuit. Since the jumper at the clutch didn't work, it must be at the Kickstand. Already did the homework and see that that's a pretty easy elimination as well....
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post #43 of 62 Old 09-18-2019, 06:07 PM Thread Starter
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Do you have a Kawasaki shop manual, or access to one?

Tom [email protected]

“It could have been a beautiful friendship. Except for the ice pick, of course.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #44 of 62 Old 09-26-2019, 01:35 PM
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Putting this as #3 on my to-do list, right after #1 getting the oil leak / smoke -on -startup solved, and #2 decalifornication.
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post #45 of 62 Old 11-14-2019, 12:48 AM
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Quote:
Originally Posted by Tom Schmitz View Post
...First, the clutch...Alternatively, you can use a mini-fuse. Flash has some photos of this done with a fuse here
Stick...the mini-fuse, into the connector at the clutch lever...Tuck the connector back into the socket...Done!...T
I was curious about this mini-fuse alternative, but the photos no longer seem to be available. Is there another thread on this mini-fuse option? Was it a 5, 10, 15, 20 amp fuse (or higher)? Anybody save Flash's instructs on this method?

Last edited by Schoen; 11-14-2019 at 12:53 AM.
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post #46 of 62 Old 11-14-2019, 02:15 AM Thread Starter
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There is no appreciable current flowing. The fuse rating does not matter; it's just a jumper. The minifuse is just a convenient way to do it rather than making the jumper.

Tom [email protected]

“It could have been a beautiful friendship. Except for the ice pick, of course.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 11-14-2019 at 02:19 AM.
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post #47 of 62 Old 11-14-2019, 10:00 AM
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I did the mini fuse, it lasted one day, its to soft. I found a piece of tin, something in the junk stuff, and cut it to fit, and pressed it in with needle nose pliers, and all went well.
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post #48 of 62 Old 11-15-2019, 06:14 PM
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Quote:
Originally Posted by lineman1234 View Post
I did the mini fuse, it lasted one day, its to soft. I found a piece of tin, something in the junk stuff, and cut it to fit, and pressed it in with needle nose pliers, and all went well.
I did the "capacitor castration" and so there's no need for a fuse, short wire or tin jumper.

Jason
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post #49 of 62 Old 11-15-2019, 07:41 PM
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And how does one do that?
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post #50 of 62 Old 11-16-2019, 06:38 AM
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Quote:
Originally Posted by Schoen View Post
And how does one do that?
I'm at an event until mid-afternoon today, but when I get back I'll look for my modified wiring diagram sketch and revert.

Jason
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