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It has been awhile, so I will say howdy first. I am still riding the KLR. I have had two electrical issues in the six months I have had her.
1 - Main fuse blew after bike set in the rain. Replaced fuse and has been ok. I keep spares.
2 - Last Sunday, I rode her to my brother's. Went to leave, wouldn't start. Ok, roll start. The lights got weaker and weaker. She dies. Since she is under warranty, I charge the battery with a 2 amp trickle for a day. 13.4 volts. Start her. 12.05, 12.04, 12.02
Rev her to 5k and hold. No increase. Take her back to Star City Powersports. I tell them what I observed. I am expecting to be down while waiting for parts. Next day, I get the call that it was fixed. The wiring harness had rubbed through in one spot and was shorted. They repaired and re-routed the harness.
Like I said, I am not getting too deep into things while I have a 5 yr warranty!!
I like my klr a lot. I even have my brother looking for one cheap.
 

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Glad to hear you got the electrical problem fixed. If I had the 5-year warranty, I'd take it back for every problem, too.

You know, I can accept some of the other faults with the way the KLR was put together, but all these wiring routing problems people report; chafed/cut/burnt wires are just ridiculous. At least Kawasaki acknowledged it on the early GenII models and did the recall, but I still don't really trust mine.

I have a 2009 and I called Kawasaki and they said there were "no recalls" on my VIN. I was hoping they were going to say, "Yes, there was one, but it's been done."

I've got the KLR in the basement this Winter and am going to go over every inch of wiring on it, checking for poor routing, adding anti-chafe measures and adding dielectric grease to all the connectors.

Glad to hear you got yours fixed and you're back out on the road.
 

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I need help !!!!!!!!!

Looking for a wiring harness for a 2004 klr 650a but i dont know if there is a difference between the klr 650ex or what trying to rebuild the bike but pack rats ate the complete harness
 

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