2009 KLR Starter Not Working After Fuse Blow - Kawasaki KLR 650 Forum
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post #1 of 14 Old 07-18-2019, 07:48 PM Thread Starter
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Join Date: Oct 2018
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2009 KLR Starter Not Working After Fuse Blow

Hoping the brilliant minds in this forum can help me!

Started the bike up. Headed out and two blocks from the house electricity died instantly. Lights, blinker, everything. Walked it back to the house. Battery has a great charge (I have the KLR Lower Dash that tells me the volt output from the battery. Fuses under the seat were good. AHA! The culprit was the 30A fuse by the starter (underneath the red rubber cover). Replaced it and the electricity is back!! Lights, blinker, everything is well.

EXCEPT the starter won't do anything. No click. No sound. No attempt to turn. Not in neutral or in 1st. I've got it on a center stand with the kick stand up.

Any thoughts?

The bike has been riding fine for months. About 3 months ago I had one of the 15A fuses under the seat go out. The starter sounds a bit strange at times but always starts right up. I'm a new rider/wrencher having bought this bike in October.

Thank you for any help!

- Judd
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post #2 of 14 Old 07-18-2019, 09:24 PM
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Re-check your main fuse, something cause it to blow the first time. Probably burned again.

Check the wires between the coolant recovery bottle bracket and the PRESS welded seam of the fuel tank on the RH side.
That bundle of wires really should have been routed Above & In Front of the coolant recovery Bracket! So it could not get chaffed or pinched.

pdwestman
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post #3 of 14 Old 07-19-2019, 09:21 AM Thread Starter
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Thanks for your response pdwestman! The fuse should still be good as I have power throughout the bike (headlight, blinkers, etc). Before I replaced the fuse I had zero electricity. I’ll check the cables you referred to. Do you have any thoughts on what the problem could be given I have solid electricity to all lights but the starter won’t make any movement at all? Obviously the starter itself could be dead. Trying to figure out how I can narrow it down.
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post #4 of 14 Old 07-19-2019, 11:53 AM
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Did you accidentally bump the kill switch & forget to check? It happens.

Luckily on most Kawasakis the kill switch kills the starter & the ignition. Some brands will allow starter cranking with a DEAD Ignition! Grrrrrrrr!

pdwestman
Modify at "YOUR OWN RISK"!

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post #5 of 14 Old 07-19-2019, 01:03 PM Thread Starter
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Forgive my ignorance but does a gen 2 have a kill switch? If so where is it located? I have the kickstand up (it’s on the centerstand) and the bike is in neutral.
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post #6 of 14 Old 07-19-2019, 03:11 PM
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Page 27 of the owner's manual.
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post #7 of 14 Old 07-19-2019, 05:05 PM
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I think Paul and Tom nailed it!

The 'ole' kill switch has been the root cause of many a bike not starting!

Jason
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post #8 of 14 Old 07-20-2019, 10:22 AM Thread Starter
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My god. As dumb as a f*ckin door nail. I always thought of that as a fuel shut off switch. I’ve been riding this bike for 9 months and always shut if off when not riding. I didn’t realize it killed the starter as well. Starter jumps to life unlike my ego which is now deflated. A good thing I suppose.

Thank you again all!
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post #9 of 14 Old 07-23-2019, 12:16 PM Thread Starter
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Wellllll...got it up and running and 1/4 of mile from home it blew again. The same 30A fuse right on the starter. I took spares and put them in one at a time trying to get back home but it blew two more fuses the instant I tried to start. I feel like the short has to be near the starter. Have Jury Duty today but going to tear the bike down Thur/Fri. If anyone has any other ideas or any insight on the best way to track down the short, let me know. Again, I very much appreciate your input.
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post #10 of 14 Old 07-24-2019, 10:09 AM
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Quote:
Originally Posted by juddfrazier View Post
Wellllll...got it up and running and 1/4 of mile from home it blew again. The same 30A fuse right on the starter. I took spares and put them in one at a time trying to get back home but it blew two more fuses the instant I tried to start. I feel like the short has to be near the starter. Have Jury Duty today but going to tear the bike down Thur/Fri. If anyone has any other ideas or any insight on the best way to track down the short, let me know. Again, I very much appreciate your input.
Quote:
Originally Posted by pdwestman View Post
Re-check your main fuse, something cause it to blow the first time. Probably burned again.

Check the wires between the coolant recovery bottle bracket and the PRESS welded seam of the fuel tank on the RH side.
That bundle of wires really should have been routed Above & In Front of the coolant recovery Bracket! So it could not get chaffed or pinched
.
Again I'll point to the most common area for damage that I know of. The RH edge of the fuel tank.

If that doesn't find the source read over here,
https://www.klrforum.com/2008-klr650...locations.html

You might even scroll to the very Bottom of this screen to check for "Similar Threads".
ps, Whoops!
When did this forum dis-continue the "Similar Threads" FUNCTION? Well next to nobody ever scrolled far enough to find it anyways.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting

Last edited by pdwestman; 07-24-2019 at 10:16 AM. Reason: ps added
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