08 KLR Electrical problem...any help apreciated! - Kawasaki KLR 650 Forum
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post #1 of 28 Old 06-19-2008, 11:23 AM Thread Starter
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08 KLR Electrical problem...any help apreciated!

I first want to say I love my new KLR.

But,

I have had some wiring problems. And I could use some help trouble shooting.

What happened, during the course of normal riding it couphed backfired and ceased to fire. I took it apart back at the camp site down to the plug and initialy couldn't get spark...but after a bit I was able to revive the spark (I checked all my conections and wiring and went over everything I could think off), reinstal and it ran for another 600k.

And then it died again in the same way. I had more time to asses this time and tore it down in the shop. At first I couldn't get spark, so I put the plug on the tester and got a somewhat weak reading. I changed the plug and bang I got spark....but...it died again right away. I pulled the plug and couldn't get spark, so I switched out for another new one and no spark right away..again some medling with the wiring some contact ceaner and poof it works again. Now that it is runing fine I am unable to re-create the problem.

Unfortunately I don't trust my bike not to kak out at any time.

I have heard of a "wire routing" problem with the wires shorting on the tank but I have not been able to find the specific fix for that problem or instructions on how one should re-route the wires.

I have visualy inspected all the wires I could find for ware but found nothing specific. I find it dificult to believe that testing with an amp meter will help if it is functioning normaly everything will be in "spec"

I believe I have a short somewhere in the system. Is there a "more comon " place I can look? Most of my problem is that it is so intermitent.

Any help I could solicit would be greatly apreciated. Thanks all in advance.
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post #2 of 28 Old 07-01-2008, 10:18 PM
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meter

You may need a mega ohm meter also known as a "megger". It tests the high voltage integrity of the insulation on your wires by putting a very high voltage at low amperage. If there is a flaw in the insulation it will find it. You need to isolate both ends of the wire you are testing so you don't fry sensitive electronic components. A good motorcycle shop should have one. We test all of the wiring in a building this way before we turn anything on to make sure that you don't blow up a panel or worse.
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post #3 of 28 Old 07-01-2008, 10:42 PM
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Or a loose ground wire on the battery or frame.
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post #4 of 28 Old 07-02-2008, 08:50 PM Thread Starter
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Found It

Thanks for your advice guys. I managed to solve the problem with a less sophisticated method.

I ran the bike with the tank still conected but up off the frame so I could access the wiring from the spark plug. After some poking with a screw driver I discovered I could stall it out and found a wire from the coil had worn against the frame through its insulation (right beside the coolant overflow resevoir) facing away from where I could see it. I wrapped the wire in electrical tape and have not had another problem with it in the last 1000 K's...I'm going with problem solved.

Thanks

Keep on riding!
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post #5 of 28 Old 07-02-2008, 08:55 PM
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Seems I have heard of others with an issue close to if not identical about having a wire grounding against the frame in that area. Something to try and keep in the back of my mind or put it into my manual under the heading of "What If"..
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post #6 of 28 Old 07-02-2008, 11:33 PM
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That is exactly the kind of thing a megger will detect. Way to get after it and find it.
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post #7 of 28 Old 02-10-2013, 10:15 AM
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I've been having the same issue! I will check this area of the coil..hope this is the problem!! Thanks for all the post !!!
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post #8 of 28 Old 02-10-2013, 11:23 AM
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Quote:
Originally Posted by repsolric View Post
I've been having the same issue! I will check this area of the coil..hope this is the problem!! Thanks for all the post !!!


Another common area to check is where the harness passes over the voltage regulator (black finned thing right side behind the coolant resoviour). The tank pinches the harness there.
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post #9 of 28 Old 02-10-2013, 03:38 PM
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Thanks again, I'll finally get to trouble shoot it today after work. I'll have a bit of day light to tinker with it!
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post #10 of 28 Old 02-12-2013, 03:31 PM
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Well I found some rubbish "where the harness passes over the voltage regulator (black finned thing right side behind the coolant resoviour)". The tank must have indeed pinched the harness. Also, found some more rubbish on the two bottom coil wires. Taped the all with some elec tape. However no bare wires showed!

Previously, I had tested and found my clutch safety relay behind the headlight non-fuctioning. it failed the test, so I bypassed the clutch and kickstand switch safety relays. Got a new spark plug and now seems to have a spark but appears "weak". I'll put the tank back on this evenig and try to start it! Gotta get this figured out and ridden for a while before my mexico trip in April! I must have a short somewhere, not visible to the eye!? Your continued assistance is greatly appreciated.
Thanks ahead.
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