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Registered
2011 KLR
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209 Posts
Dumb question, but you didn't happen to hit the kill switch on the right-hand grip assembly, did you?
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #42
OK, I’ll check that tomorrow morning after I get a bunch more fuses.
Thanks again.
Happy Easter too
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #43
Kill switch is in the run position, not a dumb question ... in my case especially there are no dumb questions. Gas was turned on too.
 

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Premium Member
2013 KLR 650/692, 2017 HD Electraglide Ultra
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908 Posts
If turning on the ignition causes the main 20A fuse to fry, then focus your efforts on the part of the electrical system downstream of the ignition switch. Something there is shorting to ground. Could be the switch itself.
 

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Premium Member
2013 KLR 650/692, 2017 HD Electraglide Ultra
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908 Posts
Important question: as there any aftermarket electrical accessories? Often those cause problems. If you have any, disconnect them and see if that restores operation.
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #46
Trail Tech, heated grips, aftermarket headlight (which blew its 5 amp fuse and then it’s bulb a few days before the current problem).
PO removed all the stock instruments and faring/headlight.
Most of the aftermarket stuff is connected directly to the battery,
The bike had been running fine except for the headlight problem until it blew its fuse ...
 

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Premium Member
2013 KLR 650/692, 2017 HD Electraglide Ultra
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908 Posts
Long experience makes me very suspicious of stuff added on by people who frequently have no idea how to do it correctly.
 

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Registered
2011 KLR
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209 Posts
I wasn't aware of this. With all that extra stuff he could have burned out his regulator since they aren't made for high wattage. Plus a bird nest of wiring running here, there, and everywhere. Take off all the doo dads and start with the basics.
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #49
Working on it over the next day or two.
Will report back ...
Thank you all
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #50
Well ... tried the brown bus test ... new 20 amp fuse, key on, 12.46 v. Lights and horn worked. Tried to start ... nothing ... fuse blown ...
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #52
Would that cause it to quit suddenly riding down the road ?
 

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Registered
2011 KLR
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209 Posts
Just depends on how/where it shorted. Everything is just fine until you hit the start button, right? Does it blow the fuze immediately or does the engine crank over for just a moment before it dies?
 

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Registered
2011 KLR
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209 Posts
Don't burn out any more fuzes, you should be able to troubleshoot this with just your meter
 

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Registered
2011 KLR
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209 Posts
And disconnect the battery ground cable before going any further
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #56
Doesn’t try to start, nothing, but the new fuse blows as soon as I try.
Will do
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #57
Done.
A guy from the Toronto Chapter of the ADV Forum who knows what he’s doing has kindly volunteered to take a look at it tomorrow.
I’m going to stop now so I don’t make it worse ...
Will update, thanks again
 

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Registered
2011 KLR
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209 Posts
There's a yellow/red wire coming out of the starter button. It heads to the starter circuit relay and the CDI. You need to disconnect it from all ends, and read it for short to ground.
 

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Premium Member
2014.5 KLR650
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133 Posts
Discussion Starter #60
We’ll check that first
 
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