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Discussion Starter · #1 ·
Helping a neighbor get his Kawasaki KLF 300b running. He got it in a non running condition. I found a short circuit from the ignition switch to the brown wire and traced it back to a wire that seems to go into the engine.
The 30A fuse blows as soon as you use the ignition switch.
I have worked on British cars like MGB's, etc. so I can usually fix most electrical issues but I have never worked on ATV's.
In the picture below it is the slimmer plastic sheathed 2 wire one.
(I know it looks pretty dirty, I just traced it down today.)
Where it comes from the main harness the wire is light green.
What am I looking at?
Thanks.
Motor vehicle Automotive tire Hood Automotive lighting Bicycle tire
 

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If the wires inside are green and red then that is for your neutral and reverse lights. The only other wires going inside the engine would be for the alternator and your ignition pickup coil.

Did you trace the brown wire from the ignition switch all the way back to the starter circuit relay?
 

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Discussion Starter · #3 ·
I used a short circuit tester and was able to isolate as best as I can tell to this green wire. I get conductivity from the brown wire at the ignition switch to this light green wire when both are disconnected from any other wires.
Somewhere this light green wire is shorted to ground. Where should I check or is this wires insulation bad and it is touching part of the case?
Thanks for your help.
 

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If the neutral switch is working correctly, then the green wire will be connected to ground while the bike is in neutral. A ground is needed in order to turn the neutral light on. Try putting the bike into gear and see if you still have continuity to ground.
 

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This is where it gets tough to remote diagnose. We have no idea exactly where or how you are testing for continuity but if the bike is in neutral, you will find continuity before and after the bulb so that is not proof of a short circuit.

If you think the green wire is causing a 30 amp fuse to blow, you should just unplug the green wire and turn ignition on.
 

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Discussion Starter · #7 ·
So finally got time to do some more testing and now when I plug in the green wire it does not blow the fuse when I put ignition on.
(I am using the Power Probe 2000 test equipment)
I tried the start switch with no results and found the starter relay is dead. I tested it and the relay clicks but no connection between the 2 power posts.
I will be getting a new one, not sure on the year of the ATV as the serial number area is rusty and only 3 number are visible!
I will match it by pictures, found one on Amazon that has the correct plug receptacle.
 

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I believe the VIN is stamped on the frame somewhere. Check out the photo in post #5 of this thread.
 

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Discussion Starter · #11 ·
Thanks, I will try the sandpaper tip, this was not a good place for a serial #, get s plenty of mud on it at this location!
Here is the one I ordered, it appears identical in appearance.
 

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The Amazon reviews indicate the plug connection is different, but the reviewer does not specify what they were installing it on. Let's hope its a perfect fit for you.
FYI OEM Kawi part is $45.
 

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Discussion Starter · #13 ·
Some progress, not sure why but moving some wires around temporarily stops the short and blowing the fuse. Replaced starter relay with Amazon one, cleaned starter motor connections and finally got the engine to crank with starter switch.
However the new starter realy is defective (just clicks, when jumping it the starter does work) and will order one from Partszilla. Based upon wiring diagram this is a 1995-1999 model.
 
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