Headlight Not Working? - Kawasaki KLR 650 Forum
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post #1 of 5 Old 08-09-2015, 06:41 PM Thread Starter
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Headlight Not Working?

Hi,

I just bought a 2011 KLR 650 and realized the left headlight doesn't work in low beam. When I switch to high beams, both headlights work. On low beams I get over 12v on the right headlight socket but only .02v on the left. Voltage is normal for both headlights in high beam. Both lights are brand new and the fuse is good. I tried shaking the wire bundles to see if there was possibly a broken/loose wire somewhere but got nothing. All other lights/turn signals work as advertised. Any ideas? Thanks in advance for the help


Also, with the fuse pulled I still get .02V on the left headlight on low beam but 0.0v on left high beam and right high/low beam. Possible short somewhere?

Last edited by Lawrimore88; 08-09-2015 at 07:01 PM.
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post #2 of 5 Old 08-10-2015, 01:25 AM
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It would be very difficult for that to happen accidentally. The red power wire to the low beam plug would have to accidentally get disconnected from the red wire to the head light fuse and accidentally reconnected to the red/black power wire to the high beam plug.

On the KLR the low beam is always on when the ignition switch is on. You can not turn it off without modifying the wiring. The headlight switch is really just an on/off switch for the high beam. It sounds to me like someone has intentionally rearranged the wiring to make that happen. Some people do things like that so they can turn all the lights off. Some think it makes it easier for the engine to start without the lights drawing power.

I would start by tracking the red wire at the low beam plug back to see where it connects to the red/black high beam plug wire. It should not make that connection.

Are you familiar with wiring diagrams?
Here is one for gen2 KLRs: KLR650.NET Forums - Your Kawasaki KLR650 Resource! - The Original KLR650 Forum!
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post #3 of 5 Old 08-27-2015, 11:45 PM
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Lawrimore88

I just bought a brand-new 2011 KLR 650 today it has the exact same problem one headlight bulb is working and one is not. surely somebody else has had this problem
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post #4 of 5 Old 08-28-2015, 01:48 AM
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Quote:
Originally Posted by Lawrimore88 View Post
Hi,

I just bought a 2011 KLR 650 and realized the left headlight doesn't work in low beam. When I switch to high beams, both headlights work. On low beams I get over 12v on the right headlight socket but only .02v on the left. Voltage is normal for both headlights in high beam. Both lights are brand new and the fuse is good. I tried shaking the wire bundles to see if there was possibly a broken/loose wire somewhere but got nothing. All other lights/turn signals work as advertised. Any ideas? Thanks in advance for the help


Also, with the fuse pulled I still get .02V on the left headlight on low beam but 0.0v on left high beam and right high/low beam. Possible short somewhere?
After revisiting this the answer just jumps out at me. On the gen2 KLR there are two headlight fixtures. The low beam is the left fixture and it is always on any time the key is on. The high beam is the right fixture and it comes on when the light switch is moved to "HIGH" while the low left side stays on. So, left only is on for low and both are on for high. They both use the identical standard H7 bulb, but the left low side is aimed lower and the right high side is aimed higher.

If the harness plugs for the light bulbs were reversed between the two fixtures, the "LOW" switch position would turn on the right high beam only and the "HIGH" switch position would then turn the left low beam on so both would then be on.

Working from memory I think the wires to the right side high beam bulb plug have a red or green tape band on them and the left side low beam plug wires have on marker band on them.

Last edited by GoMotor; 08-28-2015 at 01:52 AM.
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post #5 of 5 Old 08-28-2015, 02:03 AM
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Quote:
Originally Posted by Daphmi View Post
........... I just bought a brand-new 2011 KLR 650 today it has the exact same problem one headlight bulb is working and one is not. surely somebody else has had this problem
See post #4 for a description of how the two head lights work. In normal operation low beam operation uses the left side light low beam only and for high beam operation both the left low beam and the right high beam are used together.

If in both cases only one bulb works, either one bulb is burned out or maybe unplugged.
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