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post #1 of 8 Old 10-10-2015, 11:21 PM Thread Starter
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Talking Hello from ATL

I received my KLR today - I bought it off eBay from a seller in Florida who drove it up and gave me an introduction to it. It's totally set up how I would set it up - aftermarket suspension, bags, bars, plates, accessory plug, and center stand. I'm totally loving it.

I took it to the dealership and had new oil, filters, cable lube and adjustments done.

Afterwards, I drove it around town, but on my way home this evening, I switched the high beam switch and both headlights stopped working. The seller told me the same thing happened to him once so I knew it was the fuse.

Racing against darkness, I drove to Pep Boys, bought tools and fuses, and replaced the burnt out fuse with a 20A instead of a 15A fuse. I drove it another 10 minutes and switched into high beam, and poof...went out. I replaced it again but this time, I started the bike in High beam on (with the idea being that I'd just keep it there). It worked for about 30 minutes, but as I was almost home, I was coasting down my street in neutral. I didn't touch anything, and poof! The headlight went out.

There's lots of discussions about this, but this is a 2011 bike. Should I consider replacing the wiring harness? Is it a DIY kind of thing, or should I just pay the dealer to fix this? I'd welcome some advice. I'll post this to the forum too.
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post #2 of 8 Old 10-11-2015, 08:44 PM
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I assume that if you had a dealer change oil and filter and lube the cables, you are not the do-it-yourself type and you might want to have the dealer look at the wiring for you.

If you want to work on it, here is a gen2 wiring diagram
KLR650.NET Forums - Your Kawasaki KLR650 Resource! - The Original KLR650 Forum!

First I would go back to the original proper size fuse. That fuse is intended to be the weak link and protect the wires. It should burn before the wires burn up.

On the gen2 the low beam is always on. Since the problem occurred when you went to high beam, you should look for a short to ground in the high beam wiring. That is the red/black wire from the switch to the high beam bulb plug with a branch to the high beam indicator light. The most likely spot for a short is where the wiring bundle is routed along a support bar with some sharp edges behind the dash. Take the front faring with the headlight and windshield off to get to it. Look for some burn marks on the wires and the metal they touch.

Last edited by GoMotor; 10-11-2015 at 08:53 PM.
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post #3 of 8 Old 10-11-2015, 10:24 PM Thread Starter
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Thanks! That's exactly the advice I was looking for. The trip to the dealer was really to have them do a full check of everything - it's my first moto, but I'll wrench myself for now on.


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post #4 of 8 Old 10-11-2015, 10:34 PM Thread Starter
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Hello from ATL

Today, I had an amazing 185 mi ride in North Georgia - drove up to an off-road area that was full of soft, slippery hills, logs, and big mud pits. I dropped the bike numerous times, and got stuck in a ravine. Got a workout and learned lots of lessons. After the mud-fest, I rode it up to the Bull Mountain area and did about 25 miles off-road between Amicalola Falls and Fort Merril Ranger camp. This had a lot of slippery clay, and technical rocky downhills. My 20-years mountain biking paid off in this. Lost my odometer cable somewhere up there. Overall, it was an amazing first time out on an adventure bike. I feel like I went 7 rounds with Floyd Mayweather - can barely move now. Awesome day.


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Last edited by gtdave; 10-11-2015 at 10:36 PM.
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post #5 of 8 Old 10-12-2015, 02:02 PM
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Hello and welcome to the forums!

Congrats on the new ride!

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post #6 of 8 Old 10-12-2015, 05:50 PM Thread Starter
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Thanks y'all.


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post #7 of 8 Old 10-12-2015, 06:56 PM
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Welcome to our little mental hospital! Sounds like you're going to fit right in with us other patients!

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post #8 of 8 Old 10-12-2015, 07:54 PM
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Originally Posted by gtdave View Post
Thanks y'all.


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You're welcome, "Eh."
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