Repeatedly Blowing Headlight Fuse - Kawasaki KLR 650 Forum
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post #1 of 7 Old 07-07-2015, 06:42 PM Thread Starter
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Repeatedly Blowing Headlight Fuse

Hey guys! My son is having issues with his 2012 KLR repeatedly blowing the headlight fuse. He's pretty sure there is a short to ground, but he doesn't know exactly where to search for the short.

Any ideas?

Thanks!
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post #2 of 7 Old 07-07-2015, 07:32 PM
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Short

Good place to start:

Remove plastic, and inspect wiring harness at any place it touches metal/frame.

Start removing connectors until you find one that doesn't blow a fuse. Inspect that harness.

If you have a diagram, it would help.
https://drive.google.com/file/d/0B0B...iN2E5ZTU5/edit

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post #3 of 7 Old 07-07-2015, 08:41 PM
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I vaguely recall reading about someone having a similar problem and I thought he traced it to a rub spot in the headlight bucket area... Don't quote me on that though, I'm often wrong.

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post #4 of 7 Old 07-07-2015, 10:46 PM
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1) If it only blows the fuse when the high beam is switched on, it is in the red/black wire from the hi/lo switch to the high bulb or in the bulb itself.

2) Where the wiring bundles go under the back fender from under the seat disconnect the tail light connector (only one with three wires) and the license plate connector (two wires: red and black/yellow). Then if the fuse doesn't blow, the short is in one of those wires going back to the lights.

3) Otherwise it is in the red wire from the fuse holder through the harness to the headlight switch and out to the low beam bulb. I would look first behind the dash where the bundle runs along the small tube frame supporting the front faring and windshield.
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post #5 of 7 Old 07-08-2015, 03:54 PM Thread Starter
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Thanks for the replies, guys! I was driving when my wife was texting my son about the issues - and I posted when we were having dinner at a BBQ place. After dinner, my son sent another text saying he thought he'd figured it out.

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post #6 of 7 Old 07-08-2015, 05:01 PM
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So, what was the problem/solution?
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post #7 of 7 Old 07-08-2015, 09:11 PM
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Quote:
Originally Posted by acidman1968 View Post
Thanks for the replies, guys! I was driving when my wife was texting my son about the issues - and I posted when we were having dinner at a BBQ place. After dinner, my son sent another text saying he thought he'd figured it out.
acidman,
IF your son continues to have problems, use a H4 55/60 Headlight bulb to temporarily replace the fuse!

One can solder the High and Low contacts together and have a 115 watt NON-Burnable fuse! Use spade connectors/ or butt connectors (depending on Generation) on the wires to plug into the fuse holder.
The DOUBLE LIGHT will be Bright when Short-Circuited, DIMMER when NORMAL.

Wiggle the suspect wire harness and SEE what happens.
A lot cheaper and more effective than a hand-full of fuses!

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