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Old 7 Aug 2009
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Join Date: Feb 2006
Location: used to be Santa Cruz, Bolivia
Posts: 44
Shortcut in electrical system KLR 650. Critical!

If I was informed right all US KLR's 650 2008 models (or thereabouts) have been called back to the dealer to fix a wiring problem. They actually change the whole wiring beam I think.
In any case, just to inform you that I had a shortcut in my system that seems to fit the bill. On an extremely rainy day (of course) somewhere in Brasil the bike died. No light, no starter nothing. We found the fault. So look for it before you have this happen to you under nastier circumstances.
On the right hand side of the main frame tube under the tank (when sitting on the bike) the main cable tree/beam whatever it's called, comes from under the frame tube and bends to the right to go around the radiator reservoir. There's a bold there that holds the cable holder thingie, metal strip covered with plastic. That very bold will, or may after a while dig its way through the cable beam and cause ground shortcut. In my case it blew out the main fuse. Of course I was stupid enough to put some wiring around the fuses legs to try again upon wich the cable beam had a melt down.... off to the workshop you go....

So if ever you get you tank off, remember to wrap some extra tape around the cable beam where it rubs against the bold and you should be fine....
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Gertmans
Looking for his buddies on the South American continent
KLR 650
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Old 30 Dec 2009
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Location: since 2005 on the worldtrip,on two bikes and more than 300.000km
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nice pics and klr story

Quote:
Originally Posted by Gertmans View Post
If I was informed right all US KLR's 650 2008 models (or thereabouts) have been called back to the dealer to fix a wiring problem. They actually change the whole wiring beam I think.
In any case, just to inform you that I had a shortcut in my system that seems to fit the bill. On an extremely rainy day (of course) somewhere in Brasil the bike died. No light, no starter nothing. We found the fault. So look for it before you have this happen to you under nastier circumstances.
On the right hand side of the main frame tube under the tank (when sitting on the bike) the main cable tree/beam whatever it's called, comes from under the frame tube and bends to the right to go around the radiator reservoir. There's a bold there that holds the cable holder thingie, metal strip covered with plastic. That very bold will, or may after a while dig its way through the cable beam and cause ground shortcut. In my case it blew out the main fuse. Of course I was stupid enough to put some wiring around the fuses legs to try again upon wich the cable beam had a melt down.... off to the workshop you go....

So if ever you get you tank off, remember to wrap some extra tape around the cable beam where it rubs against the bold and you should be fine....

hello gertmains
bolivia,very interessted,
next year I shipp over from Newzealand to Chile,maybe we can catch up,when I arrived in Bolivia,you can show me some good rides,
best for 2010,
fredontour,with the green 08,Klr
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