Originally Posted by RandoCommando
The 2008 and newer KLRs had an issue with the wiring harness rubbing in certain spots.
Did you have the recall done for the armoring?
2009 KLR, had the "recall" done on this model. But there were a few areas that they still didn't get. One area said the front fairing, so took that off and found a tiny little cut on one of the wires. It was being rubbed on the soft metal hold down. That little wire kept shorting the main fuse as soon as it got power. Taped it up good, put the fuse back and bike starts fine.
This spot, looking at the front of the bike sans fairings.
Tiny little rub-through
The culprit - Note the two sparky areas.