Question about 2003 kawasaki KLR 250
Hi, Debra before diagnosing your blown fuse issue, check the bottom of your seat, if its metal and comes in close proximity to the positive battery post you need to take the necessary steps to ensure there is no contact (electrical tape, thick rubber insulation, hammer a dent in the seat bottom, etc.) You are going to need a wiring diagram from your service manual, a test light, an ohmmeter and plenty of extra fuses.
If you turn on your ignition switch and immediately blow a fuse you have a hard/dead short and is usually easy to find. With a test light connected to the hot side of the blown fuse holder start stabbing the wire/s that leads away from the fuse holder and towards the ignition switch, you test light will illuminate validating the short. When the test light fails to illuminate you have passed the short and need to back up until the test light illuminates, then look in the immediate area for the short.
If you driving down the road for 30 minutes or 15 miles and blow a fuse you have soft/flying short and may take some time and patience to find.
If the main fuse/circuit breaker constantly blows/trips while riding you probably have a faulty battery terminal connection. Check battery terminals for damage or corrosion, check battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary. Any other fuses that constantly keep blowing while riding are usually caused by a loose or corroded ground wire in the circuit, which means you have to check, inspect, test each and everyone with an ohmmeter set on a low ohm scale 100 ohms or less . Simply touch one lead to the ground source and the other lead to the battery negative terminal, a reading of zero indicates a clean solid ground. Any reading or infinity indicates a poor ground and needs to be repaired. Poor or weak grounds require excessive additional amperage to complete the circuit which in turn blows the small amperage fuse.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Kawasaki KLR 250 Service Manual Supplement
OEM Parts for Kawasaki
KAWASAKI EL250 Owner Manual
Posted on Jul 21, 2019
not sure if this will help, but the crank case has a breather tube that is around that area. if the bike is on its side or has been doing wheelies, some oil can get thru the breather hose causing that problem.
Posted on May 07, 2009
SOURCE: kawasaki klr250
when was the last time the valves where adusted?klrs are famous for needing inlet valves replaced,when kicking bike over listen for hissing from airbox /exhaust indicating an inlet valve s problem loss of compression when starting
Posted on Apr 23, 2016
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