Klr electrical work - Kawasaki KLR 650 Forum
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post #1 of 14 Old 11-05-2014, 09:59 AM Thread Starter
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Klr electrical work

On my 09 kawasaki Klr I've been having some electrical problems, mainly my speedo and tachometer are not lighting up. I also noticed that when I put the kick stand down that it does not shut off the bike. I read about "electrical armoring" basically covering wear spots on wiring with electrical tape. Think this could be a problem with some of my electrical issues?
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post #2 of 14 Old 11-05-2014, 12:58 PM
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That can never be a goodthing. My son has a Harley Nightster that blew the main fuse.
A wire from the switch was testing against the head. From the heat and vibration it wore off the insulation and shorted out. Electrical tape fixed the issue to get him home.
I went to Radio Shack and grabbed a small package of wire wrap. 8 inches installed in seconds and did the trick.
It is available in a variety of colors.
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post #3 of 14 Old 11-05-2014, 01:51 PM
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Quote:
Originally Posted by Nate16guy View Post
On my 09 kawasaki Klr I've been having some electrical problems, mainly my speedo and tachometer are not lighting up. I also noticed that when I put the kick stand down that it does not shut off the bike. I read about "electrical armoring" basically covering wear spots on wiring with electrical tape. Think this could be a problem with some of my electrical issues?
Electrical shorting is not likely the problem with your lights because a short that would kill the dash lights would blow a fuse. When lights don't work the first thing I suspect is the bulbs. Have you checked the dash light bulbs?

If the engine continues to run IN GEAR when the stand is down, the neutral switch light green wire or the side stand switch light green wire is shorted to ground either accidentally or intentionally. Any chance a previous owner jumped out the stand switch intentionally due to intermittent operation of the switch?
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post #4 of 14 Old 11-05-2014, 05:02 PM Thread Starter
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I have not checked the bulbs yet, I am going to tear into it this weekend and see, my guess is that the speedo and the tachometer share a common ground so that will be what I look at first. If everything seems fine their ill check the bulbs. But the rest of the dash lights, nuetral light, high beem indicator, all work fine. While i have it apart I'll check wiring wear spots and see what I can do to fix that, if their are any.
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post #5 of 14 Old 11-06-2014, 10:54 AM
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A multimeter and this link to a wiring diagram should provide keys to solve the problem:

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post #6 of 14 Old 11-06-2014, 11:30 AM
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Great resource. I could use this too! Thanks!
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post #7 of 14 Old 11-06-2014, 02:16 PM
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Originally Posted by Nate16guy View Post
I have not checked the bulbs yet, I am going to tear into it this weekend and see, my guess is that the speedo and the tachometer share a common ground so that will be what I look at first. If everything seems fine their ill check the bulbs. But the rest of the dash lights, nuetral light, high beem indicator, all work fine. While i have it apart I'll check wiring wear spots and see what I can do to fix that, if their are any.
They do share a common ground along with several other dash lights. If the ground were bad, the other dash lights would be out too.

Here is another diagram that might help you. I keep a copy of it on waterproof paper in the pouch with my proof of insurance. It saved my bacon one dark night 2,000 miles from home. http://www.klr650.net/forums/attachm...3&d=1251918868
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post #8 of 14 Old 11-07-2014, 10:01 AM Thread Starter
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Good to know, Is there any immediate way to tell if the groundings are bad? im going to start taking off panels to get to the dash wiring Saturday or sunday.
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post #9 of 14 Old 11-07-2014, 12:50 PM
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As I said above the THREE meter lights including speedometer and tachtach lights in addition to the temp and tachometer gauges (the instruments not the lights) and high beam indicator lights all share a common ground wire to the dash. If that wire had a bad connection, all the above would be off. If you had a loose ground problem, it would have to be two separate problems in the short individual Black/Yellow ground wires going to the two individual lights that are out.

The THREE meter lights are served by a single RED 12 volt power wire that does not serve other devices. If that wire were "open"/ broken those the THREE meter lights only would be off.

I can't make a case for a shorted wire causing your problem. If a ground wire is shorted to ground, it is still ground. If hot wire is shorted to ground, it would blow a fuse and take out everything served by the fuse.

In the wiring diagram I linked above, look at the upper left hand corner and you will see the THREE meter lights and the other dash devices. The Black/Yellow wire is the common ground wire throughout the entire wiring harness of the KLR.

Once you have the back of the dash exposed it is easiest to pull the THREE dash light bulbs out from the back and see if they are burned out. Each of the sockets holding the bulbs has two wires (Red 12 volt power and Black/Yellow ground). You can pull the socket from the back of the dash and then pull the bulb from the socket. You can also check for 12 volts between the two contacts in the socket. Don't short between the contacts or you will blow a fuse.

Last edited by GoMotor; 11-07-2014 at 12:56 PM.
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post #10 of 14 Old 11-07-2014, 09:48 PM
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Good to know, Is there any immediate way to tell if the groundings are bad?
Yes.

With multimeter set on RESISTANCE, measure ohms between bulb ground connection and battery negative terminal or clean metal surface of frame. Oughta be low!
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