Electrical Problem - Erratic tacho, lights & a little misfire? - 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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  • 1 Post By Aussie11KLR
  • 2 Post By GoMotor
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post #1 of 9 Old 07-26-2016, 06:57 PM Thread Starter
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Electrical Problem - Erratic tacho, lights & a little misfire?

Hi all, new member with a little issue that's just started...

So I'll be riding along and suddenly the tacho either goes dead or starts bouncing around like crazy flicking randomly from zero to redline, etc. at the same time the indicators seem to be affected, flashing an erratic pattern when I put them on (I think, hard to tell). Also when this is happening the engine seems to “skip” a little, especially if I'm revving from idle.

This problem seems to come on randomly then cure itself for a bit, then start up again. If I give the bike a good rev out through the gears it still seems to run okay.

What do you recon? Faulty coil / CDI / loose ground?

It's a 2011 that's pretty stock. Going to give it a going over tomorrow.

UPDATE: Just rode home from work, it was fine for the first half hour then I flicked the high beam switch and it started to mess up again with the crazy tacho! I flicked between high and low beam and the problem came on and went away with it, weird... Grrrrr... I put a new headlight bulb in on the weekend and it was fine before that. Maybe I screwed something up?


Help!
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Last edited by Aussie11KLR; 07-27-2016 at 03:08 AM.
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post #2 of 9 Old 07-26-2016, 08:07 PM
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Not a loose ground because the neutral light has its own separate ground through the neutral switch.
Not the coil or the ignitor (gen2 has an ignitor not a CDI) because that would not affect the indicators.

Seems like a loose 12 volt power wire or connector. So, something on the brown or white wires. I would first check the 4 wire connector on the four wires leading to the ignition switch.

The more things you can find that are affected (horn, headlight, dash lights, tail light brake light), the easier to track it down.

Do you have a wiring diagram?
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post #3 of 9 Old 07-26-2016, 08:37 PM Thread Starter
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Thanks. Hopefully it's just a loose connection somewhere. Would that affect the way the bike runs though as well as the tacho, lights, etc? I've never delved into the KLR wiring before so not sure where to start... I have a manual so the wiring diagram should be in there.
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post #4 of 9 Old 07-26-2016, 09:21 PM
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The gen2 KLR ignition runs off of 12 volt power from the battery not the rotor coils like the gen1, so a break in the 12 volt wiring from the battery and regulator/rectifier to the ignitor would stop the spark. It would also stop other things such turn signals, headlights, dash lights.......... depending on where the break is.

Like I said a bad ground would not affect the neutral light.
Here is the diagram I use: http://www.klr650.net/forums/attachm...3&d=1251918868

It doesn't necessarily indicate the proper location of components. For example the turn signal relay shows to be near the taillights but is actually behind the dash.
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post #5 of 9 Old 07-27-2016, 08:13 AM
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If ur bike was fine before installing the new bulb, then I believe that it's from the install.
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post #6 of 9 Old 07-27-2016, 01:13 PM
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I thought your original post said the neutral light went out with the problem, but I just reread it and see nothing about the neutral light. So, forget my comment about the neutral light going off indicating the problem is not ground related.

You might learn something with a volt meter across the battery when the problem is occurring.
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post #7 of 9 Old 07-28-2016, 03:51 AM Thread Starter
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Okay so I pulled a few panels off today and found that the connection to the negative battery terminal was super loose, like wiggling around with my finger loose. Also found the cig lighter port hard wired to both terminals. Took this off as I don't need it. Tightened everything back up (plus Loctite) and went for a spin. Bike seemed fine, but it was only a short ride so will keep an eye on things over my next longer ride.
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post #8 of 9 Old 07-28-2016, 09:39 AM
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The surprising thing about the loose battery connection is that it did not cause you to mention starting problems like he main starter relay (solenoid) just clicking or chattering, but not turning the starter when you press the start button.
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post #9 of 9 Old 08-02-2016, 03:29 AM Thread Starter
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Well it seems like the loose battery terminal was the culprit as the bike has run fine this week.
Thanks for all the input.


Quote:
Originally Posted by GoMotor View Post
The surprising thing about the loose battery connection is that it did not cause you to mention starting problems like he main starter relay (solenoid) just clicking or chattering, but not turning the starter when you press the start button.
Yeah it always started fine. Maybe if it had continued to work even looser it would have started to cause those problems. I got investigating after only two rides with the issue!
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