1991 Klr650 Rebuil!!! - Kawasaki KLR 650 Forum
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post #1 of 8 Old 02-09-2009, 12:02 PM Thread Starter
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1991 Klr650 Rebuil!!!

I aquired a 1991 KLR650 that is not running.
I have done:
oil and filter
air cleaner
spark plug
battery
IMS 6.6 gas tank
rebuilt pitcok (working)
rebuilt carb(possibly working?)

No signs of life at all! No signs of juice.

Where do I begin on the electrical?

Any and all info would be appreciated!!!!!!
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post #2 of 8 Old 02-09-2009, 04:37 PM
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You obviously have some know-how. If you don't have a Clymer manual, I'll highly recommend one.

Start simple. Make sure you have a good ground from the battery and go from there. Work upstream on the hotside (also checking ground at each component). Hoping it's just a fuse, connector or cable.

And welcome.

Edit - and first, verify the battery is good even if it's new.
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post #3 of 8 Old 02-09-2009, 05:34 PM Thread Starter
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You Rock! Thanks

Dear Big Iron,
That seems to be the consensus. Start from the Battery and work to the front. Can I down load the manual somewhere trustworthy?
I am goning to get a good 12v test light to probe with!
Thanks for the encouragement!
Ken
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post #4 of 8 Old 02-09-2009, 06:04 PM
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Make sure the male/female connector where the fuses are located at above the battery has good connection. Mine died one day and had no sign of electrical current to anything. The connector looked connected, but I pulled it apart and pushed it back together and everything worked like a dream. Ended up putting a small zip tie on it to keep it from having the issue again.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 8 Old 02-09-2009, 07:07 PM Thread Starter
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Great place to start.
Is that the only fuses on the Bike?
Thanks
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post #6 of 8 Old 02-09-2009, 09:37 PM
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There is one on the front right side behind the front tank fairing for the radiator fan.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote
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post #7 of 8 Old 02-10-2009, 10:00 AM
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This is the most comprehensive electrical fault finder I have used. It hasn't let me down yet. It belongs in every manual. I tried to upload the file but had no success.

http://www.electrosport.com/technica...ng-diagram.pdf

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

This information makes it much easier for other members to answer/comment on your posts.
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post #8 of 8 Old 02-10-2009, 10:17 AM
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Most excellent. thanks.
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