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Old 01-17-2013, 11:42 PM   #11
Leisure Engineer
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Joined: Oct 2010
Location: Portland...the newer one on the left side.
Oddometer: 2,956
Originally Posted by RandoCommando View Post
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.
2014 KTM 690R, 2009 KLR650, 2004 KTM 450 EXC, 2000 R1150GS

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