I NEED A WIRING DIAGRAM FOR 2008 KLR 650. I HAVE BURNT SOME WIRES COMING FROM THE IGNITION TO THE MAIN FUSE. MELTED TOGETHER, SEEMS LIKE THE WIRES UNDER THE TANK GOT CHAFED AND CAUSED A SHORT IN THE SYSTEM. NOT SURE IF THE PRE 2008 WIRING DIAGRAMS ARE THE SAME.
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ASSUMMING THE BIKE IS 12 VOLTS WITH A NEGATIVE GROUND;
1. with a voltmeter check across the battery terminals and see that it has about 12-12.6 volts. If it does not then charge or replace the battery first.
2. Check the fuses; most bikes have a main fuse coming off of the battery or in the fuse box.
3. If the battery and fuses appears ok, check for loose or corroded terminals. Also look for connectors and wires that are corroded and/or have a melted look.
4. If everything before this checks out ok, check for 12 power at the back of the ignition switch.
5. At this point it is best that you have a wiring diagram to determine which wires carry power away from the ignition switch. Turn the ignition switch on and continue to track the power wires to where ever they go. When the ignition switch is turned on it should have some wires measuring 12 volts coming off of the switch or the switch is bad. Continue to track wires until they reach there source or a point that no longer has 12 volts and that will be the problem area.
well if your wires fried then your battery was around 20v which means your voltage regulator was bad. you need to purchase a new one of those as well. as for the wiring diagram, if the wires around the battery had been fried. are they intact or completely burnt without you being able to locate to which each wire connects to?
Check for 230Volts across terminals 1 and 2. Test that wires are not loose. Otherwise, it does not seem much can cause timer to fail, unless there was a power surge that melted wires, or cause wires in main panel to get loose..
Battery can colapse and die instantly .
Test your battery first by unplugging it and run a wire from the positive to negative and see if it spark ,
If it does nothing ...its dead
if it spark , check the main fuse .
Check all these and get back to me and if you have not found your problem i will try to give you advises
I would definitely get a good manual with wiring diagrams. Make sure the CDI has power and ground to the proper CDI input wires, and that all wiring connections are tight. I'm assuming the battery is charged and the starter spins the motor over nicely. There may also be a throttle position switch which will kill the ignition if it senses a discrepancy in the throttle cable position. Try twisting open the throttle while cranking and you may get spark in a position other than idle. Jordan
Have you checked the 30amp BLO fuse in the engine compartment fuse box? Might want to replace the blower relay too. Did you find the part or wire that melted? The wiring diagram is available at http://www.bbbind.com/free_tsb.html