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Old 10 Aug 2013
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Join Date: Jun 2007
Location: Colombia
Posts: 52
KLR Mysterious Horn Problem

Hi all,

The bike is a 2012 KLR650 with about 24,000 miles

I was riding the other day through a usual heavy storm on the Argentinian Pampas , when my horn started to mysteriously keep going off by itself.

To stop it I would tap the horn button a few times and it kind of stopped it. But later on in the day it kept happening again, until eventually the horn just kept on, it was driving me crazy and freaking out the people on the side of the road, so I pulled over and disconnected the two wires that connect onto horn assembly in the front inside the fairing - to stop the sound.

I think I checked and or/ replaced the fuse as well.

I'm getting the parts from the USA but don't want to get the wrong ones.

I was thinking the problem was either
1) The actual horn mounted brass disk assembly is broken
2) The assembly inside the horn button is faulty, has something jammed in it or the contacts stuck

maybe water influx has triggered one of the faults?

Can anyone suggest what the problem may be? or has had the same problem on another bike?

The bike is in Uruguay and I'm in Colombia so I cant check it, I just need to get the right parts - or method to fix it.

your advice is great fully appreciated ! thanks in advance

Last edited by sellheim; 26 Aug 2013 at 19:45.
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Old 12 Aug 2013
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Your bike should have two wire going to the horn, black and brown. If you take a test light you will find that the brown wire is hot when you turn your ignition switch on. The horn button completes the grounding to the horn through the black wire. To test the switch put your test light across the two wires [brown and black]. With the ignition switch on push the horn button. If the light goes on and off with the button the wiring is okay. If the light stays on then your have a pinched wire grounding out or a bad switch. One more thing to check is the black wire that plugs into the horn. Look at the rubber boot around the spade connector of the black wire. If it is missing or chaffed through it could be grounding on the metal bracket behind the horn. If so take electrical tape and wrap it around the spade connector. The horn is kind of floppy and it may have rubbed through the boot on that black wire.
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