Ignition fuse blowing bike dieing - 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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post #1 of 3 Old 11-18-2018, 04:22 PM Thread Starter
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Ignition fuse blowing bike dieing

Just last month my ignition fuse began to pop during normal operation, thus causing the bike to die. I have spent a little time trying to trace wires around to see if something is grounding out or something but can't seem to find and obvious problem. Anyone know what might be at fault here?
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post #2 of 3 Old 11-18-2018, 04:52 PM
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Gen 1, or Gen 2? Early Gen 2s had an issue with sharp edges on the frame rubbing through the wiring loom right in the area of the voltage regulator/horn. You're on the right track, but finding the short to ground can be tedious.

Let us know what year the bike is and exactly which fuse is blowing.
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post #3 of 3 Old 11-19-2018, 08:26 PM
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Make some jumper leads which can temporarily plug into the fuse box. Connect the jumper leads to a 60 watt headlight bulb.
The HL bulb will glow dim with less than 5 amps of current going thru it, then when one wiggles the harness just wrong (right?) and contacts the shorted area it will burn Full Bright!

But it Will Not Burn OUT.

Even connected between the battery and the main cable (pull the light fuse) the starter motor can't burn it, but the starter motor won't actually operate on a mere 5 amps / 60 watts. You will only hear the starter relay 'click' & the HL bulb will go full bright.

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