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99 KLR blowing main fuse

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Rigid

Rigid

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Joined
Aug 22, 2018
Messages
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Location
CANYON
First Name
Lane
Last Name
Turner
I am pretty new at this, I have a KLR 650 it is blowing the 20 amp fuse I did replace the fuse holder with a blade fuse, Lights and turns will act funny, but the bike will still run, everything I read says the bike should die, but both times I was able to ride home. The 15 amp fuse is not blowing. Any thoughts or directions would be appreciated
 
I have a 2008 that blew the primary fuse continuously. The entire bike was dead. I was at a loss so I just started tracing wires. After much effort I found a wire that was shorting out against the frame. I’ll see if I can find some pictures for you.


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My apologies. After reading your post again, you clearly have a different issue than what I had but if I were a betting man, I would bet that it’s a wire that is shorting out due to rubbing against the frame.


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dmanhart said:
My apologies. After reading your post again, you clearly have a different issue than what I had but if I were a betting man, I would bet that it’s a wire that is shorting out due to rubbing against the frame.


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Click to expand...

And probably under seat pan area.
 
Windmill said:
And probably under seat pan area.
Click to expand...
The same thing happened to me, and when I investigated I found a wire that was swinging a little wide from where it should have been and getting pinched between the seat pan and the frame. I fixed and relocated that wire and it has been trouble free for years now.
 
Well I pulled the seat and tank, didn't find anything that I believe was shorting out, I did put some of the plastic conduit around the main wiring harness where I could, I do not believe it is in the lights or the lights wiring because have not blown the 10 amp fuse. I guess I will drive and see what happens.
 
Does the fuse blow in correspondance with a known action (turning on the key, hitting bumps, turning on lights, etc) or is it sporadic?




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I haven't been able to tell, because the bike continues to run, which is good because I am not broke down on the side of the road. The only way to tell while riding is the lights and blinkers act strange, but I do want to try a few things like go down a dirt road stretch then stop and check the fuse.
 
Go back to where you started. WHY did you modify the wiring for a blade fuse holder? Look at ALL the wires you modified, AND touched. As Bill said, close inspection of wiring is needed. Good luck!
 
I have ridden about 4 or 5 times now once about 5 miles on dirt road, have not blown a fuse, possibly I fixed with the plastic conduit, but I would really like to have found it, but I will keep a watch. Thanks for your input.
 
I had a problem line that with a 2007 found a wire pinched between the rear fender and frame that wore through and shorted on the frame.

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