Wiring short - 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 23 Old 12-31-2010, 05:43 PM Thread Starter
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Wiring short

I have an '09 KLR with a short somewhere in the wiring. It's an intermittent miss and does not happen all the time. I can't seem to find it. Any help will be appreciated.
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post #2 of 23 Old 12-31-2010, 07:04 PM
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Miss, as in misfiring? Either way there is a recall on the wiring harness that Kawi will do on their dime.

Gray-haired riders donít get that way from pure luck.

Unknown
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post #3 of 23 Old 12-31-2010, 07:04 PM
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The first thing I would check is the negative on your battery ground to the frame
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post #4 of 23 Old 12-31-2010, 08:01 PM
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Hello Mr. Jones, and welcome to the forum. Intermittent miss could be wiring. Could be in the fuel delivery system. As there is a recall on your bike's wiring, I would get that out of the way first off.


Quote:
Vehicle Make / Model: Model Year(s):
KAWASAKI / KL650E 2008-2009

Manufacturer: KAWASAKI MOTORS CORP., U.S.A. Mfr's Report Date: FEB 19, 2009

NHTSA CAMPAIGN ID Number: 09V062000 N/A

NHTSA Action Number: N/A

Component: ELECTRICAL SYSTEM:WIRING

Potential Number of Units Affected:

Summary:
KAWASAKI IS RECALLING MY 2008-2009 KLR 650 (KL650E8F/L, KL650E9F/L) MOTORCYCLES. WIRES IN THE WIRING HARNESS MIGHT BE DAMAGED DUE TO RUBBING CONTACT WITH A PORTION OF THE MOTORCYCLE FRAME.

Consequence:
THIS COULD RESULT IN LOSS OF ELECTRICAL POWER TO THE ENGINE CREATING A RISK OF A CRASH RESULTING IN INJURY OR DEATH.

Remedy:
DEALERS WILL INSPECT AND IF NECESSARY REPLACE THE MAIN WIRING HARNESS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 24, 2009. OWNER MAY CONTACT KAWASAKI AT 866-802-9381.

Notes:
CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO http://HTTP://WWW.SAFERCAR.GOV
Again, welcome aboard!

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post #5 of 23 Old 12-31-2010, 08:09 PM Thread Starter
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Wiring Short

Appreciate the immediate response, I will look in to the megative ground wiring short first thing in the morning. As far as having the wiring harness replaced, I live deep in the Ozarks and most of our Kawasaki shops I wouldn't let the mechanics change a plug on my bike.
I once saw pictures on this site of areas to check for shorts. If you know where I can find those pictures again, I would appreciate it.
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post #6 of 23 Old 12-31-2010, 08:27 PM
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Quote:
Originally Posted by Harvey Jones View Post
Appreciate the immediate response, I will look in to the megative ground wiring short first thing in the morning. As far as having the wiring harness replaced, I live deep in the Ozarks and most of our Kawasaki shops I wouldn't let the mechanics change a plug on my bike.
I once saw pictures on this site of areas to check for shorts. If you know where I can find those pictures again, I would appreciate it.

Check (er... disable) the side stand switch first. Just read of someone that was chasing start up backfiring problems. He tore into the carb, checked the valves, etc. turned out the safety switch was intermitent.

My wiring harness (08) had a short right above the voltage regulator (black finned thing right side behind the radiator). The harness runs over the edge of the bracket and the tank sits down on it. I put some additional plastic loom on the harness in that spot.

The harness recal doesn't replace the harness. It's re-routed a bit and extra insulation is added in spots.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #7 of 23 Old 01-01-2011, 10:37 AM
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Wiring short

My '08 had a short in the power wire for the instrument
Back lighting. It caused an intermittent flickering of the back light, until
One day in a downpour it finally popped the main fuse.
Left me stranded waitin on a truck to get my junk to my shop.
Harvey Jones, What kind of symptoms are you getting in this 'intermittent'
Occurrence?

'08 KLR650,
'72 BMW R75/5 (Col. Klink),
'02 KTM 400 E/XC,
'05 ktm 125 sx (for sale)

"Hey, are you okay? Can you get up?
I thought you said you could ride"

All the best
Kent Soignier
www.gmdatl.com
the str8ner
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post #8 of 23 Old 01-01-2011, 02:00 PM Thread Starter
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Kent,
The signs are, a direct miss under load. Sometimes it even shuts down the ignition system. I have removed the clutch and kickstand bypass switchs so I know that is not the problem. I had the 685 kit put on so maybe when the tank was off I pinched one of the wires and it grounded out. It does not do it all the time. I appreciate all of your suggestions. I will pull the tank off tomorrow and start retracing everything.

Harvey
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post #9 of 23 Old 01-01-2011, 04:06 PM
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Recall pdf

This may be helpful
Attached Files
File Type: pdf Harness Recall.pdf (916.8 KB, 35 views)

Gray-haired riders donít get that way from pure luck.

Unknown
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post #10 of 23 Old 01-01-2011, 07:54 PM
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You can use this link to see if the recall was done on your bike. You'll need the VIN.
http://www.kawasaki.com/RecallSafetyInfo/Landing.aspx

Roger Smith
2009 KLR650
2005 ST1300
2004 DRZ400S
1973 CL350K5
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