KLR Main Fuse blown - Kawasaki KLR 650 Forum
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post #1 of 8 Old 02-14-2019, 05:04 PM Thread Starter
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KLR Main Fuse blown

Hi all. Tonight my KLR just died on me while driving down the road and after a struggle to finding a new fuse as the main fuse blew the starter would not engage. I ended up push starting the bike as I had to get it out of that area, but then about 50m up the road the bike completely died on me again. Any idea what it could be?
I figured it is an issue with the wiring loom, but maybe someone can point me into the right direction of where to have a closer look to sort out the problem.
Its a 2008 model.
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post #2 of 8 Old 02-14-2019, 05:51 PM
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The early Gen 2 (New Shape to you, I suppose) KLRs had issues with chafing of the wiring harness that caused shorts. The chafing occurred up near the area around the horn where the harness went over some sharp edges on some bracketry. There was a factory recall that, to my knowledge, is still in effect. You could take it to a dealer and get it looked at, but it is not all that hard to take care of.

Is your bike stock, or has it had some electrical stuff added? If it has stuff added, start there to see if that's where the problem might be.

To look at the stock harness you need to pull the tank and start looking at the harness for areas where the harness tape has chafed away and find the short, then repair it and make some changes so that it won't happen again.

These pictures may be of some help. Please note that they are old pictures from 10 years back. @pdwestman has some further thoughts.

You'll be looking for something like this:


Or, worse, like this:


These are some of the problem areas:


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post #3 of 8 Old 02-14-2019, 06:16 PM
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The main harness as it leaves from behind the coolant reservoir over to the Right fairing panel can get Trapped/Chaffed between the reservoir Bracket and the seam of the fuel tank.

I remove the top of that bracket from frame and re-route the main harness to In-Front of and Above the reservoir bracket.

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post #4 of 8 Old 02-14-2019, 06:19 PM
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Toms 3rd pic shows the harness behind & below the reservoir bracket. As in factory routing.

pdwestman
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Still riding my 1987 KL650-A1. 83,000+ miles & counting
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post #5 of 8 Old 02-15-2019, 02:47 AM Thread Starter
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Thank you all! I will have a look later on when I have time to take it all apart and get back with some pictures hopefully
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post #6 of 8 Old 02-15-2019, 04:35 PM Thread Starter
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I took the bike apart and found one or two wires that were burnt a bit, but they were already taped up before. Other than that there was some gunk on the positive terminal of the starter that might have been an issue. Took it for a quick test drive and all seemed fine until now.
Thanks for all the help guys!
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post #7 of 8 Old 02-15-2019, 06:21 PM
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Well, check the battery terminals for tightness and the terminal on the main fuse block, too.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #8 of 8 Old 04-23-2019, 02:59 PM
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Quote:
Originally Posted by pdwestman View Post
Toms 3rd pic shows the harness behind & below the reservoir bracket. As in factory routing.
Does anyone have a picture of the harness relocated as described by Paul?
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