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Old 9 Feb 2007
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KLE Electrical fault!


Am i glad i finally found a KLE forum!

I have an electrical problem.

When the ignition was turned on there was no lights lighting up.
I have pulled it apart, and replaced the starter solenoid (as it had been playing up).
Still no joy.
The only way i have managed to get it going is by cutting the white wire that goes on the starter solenoid, and putting it directly on to the battery.
When the ignition is turned on i get lights and it fires straight up on the button........
I am really puzzled by this as it is not as it should be.

Is the white wire the one that carries the power to the ignition switch?
Can anyone put their finger on the problem.....its really getting to me now as i cant figure it out!!

hope you can help



p.s Thanks in advance
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Old 10 Feb 2007
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I have no idea what your fault is, but the service manual is available at http://www.motocikli.com/files/kle500manual.pdf

Hope that helps.
"On that? You're nuts!" - My cousin's boyfriend

Current Bikes - Kawasaki KLE500 '05 (May 06)
Previous Bikes - Hyosung GF125 (Oct 05 to May 06)
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Old 10 Feb 2007
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Have you checked the ignition switch itself? Someone else has mentioned that it needs a resistor,otherwise it would not start, which means that you cannot hotwire the bike.
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Old 10 Feb 2007
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I have sorted it now.

The white wire is now fed directly by the battery, i have put an inline 30 amp fuse on that.

got it all running and discovered it was not charging.

Checked out the wiring and discovered that the same white wire also goes to the regulator, and the connection was rotten.

so i have now soldered all of the wire and its now charging at around 13.46v which is great.
so its all sorted now.......just need to pop service the calipers and get an mot then i'm back on the road.

I have heard that the white wire rots, but dont know why it does... ?

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Old 12 Feb 2007
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Electrical problem

Hello Scotty.

Please check the KLE tips and tricks forum for the electrical problem I had as well. Also download the pdf file from the link I posted there. I had 2x bad connections, including that white wire, on the connector under the the tank. Clean out and lubricate that block, and any others you can lay your hands on. Please follow that charging faultfinding diagram, as this bike does not run with a flat battery, and a new regulator is about $200USD.


If its stupid, but it works, it aint stupid.
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