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James, My reading may be a little higher due to the fact that the only thing I have that is constantly on is the Autocom, Zumo GPS, and Radar Detector. Nothing else. Bob

After catching up on the recent posts I now need to go and take 2 Aspirin. But the good news is I took the bike to work today. I saw a momentary 14.35V on fast idle when cold and during the slowish 45 min ride to work it hovered between 14.15V and 14.25V with RPM's between 2500 and 3K. This...

I think the wire needs to be tested under a load. An ohm meter is no good. Even a tiny wire has continuity. I think there is a tester called a Megger. It not only tests continuity but also load capacity? I'm not sure. Where is Alan?

Ouch! I feel like stick man #2 in your avatar. But your right. The Gen 2 wiring is a disaster.

I inspected and cleaned all those 2 years ago and replaced the main fuse which had a little corrosion in it. I gained .1V Run a new wire Art. You will be thrilled with the results. Better than new! This issue is going to turn out just like the spider grounds. Sooner or later it will get everyone.

I have been chasing this problem for a few years. Each year it gets a little worse, but never to the point of not starting. It did get to the point of not being able to run the heated gear it used to run just fine. This year it deteriorated to the point that the fans were causing a discharge...

I would love to give you some technical explanation as to why it is a good idea to re-ground the original ground wire from the RR. But truth is I just guessed it was a good idea. I just thought that if there are any system grounds on that wire on its path to the battery then grounding both ends...

Finally stopped raining so I got it out and ran till the fans came on. At first start it was 14.2 at high idle, then settled down to 14.0 at idle. When the fans came on it was 13.6 at idle,(1100 RPMS) and 13.9 at 2500 RPMS, . Before the fix it was 12.9 at idle with the fans and no improvement...

Many thanks to you Don and James.   I have been having this same problem for a few years and it got worse each year. Mine was at the point where it was running 13.6 on the road, but would drop to 12.9 if the fans came on. Increasing RPM's with the fans on would not help much. Heated gear was...

There are 3 bearing/shaft assemblies in the pivot casting, (bushing), mulitiplier, whatever you call that thing, and another bearing/shaft assy on the swing arm. When my bike was a year old I pulled it all apart and lubed everything including the swing arm pivots. 50K later I did it again only...

I am just guessing here but I find it hard to believe the engine has real damage. I'd take off the throttle body and suck the runners out clean with a shop vac. Then pull the plugs and suck out the cylinders while turning it over. Then squirt oil in the cylinders to restore the compression which...

I think the cheapest way out of this is to buy a new one off e-bay for $400. Except for an 06 in the correct blue they are going for $600. So I think I'll get a new one the wrong color and just swap the lids so the color matches. I suspect the new ones are made stronger? We got the metal plate...

Yeah, your kinda right there. :)

Took pics of the top box cracks and sent them to the dealer so he could forward them to Mama Yamaha. We"ll see what happens.

You might be a KLR owner if: You are often disappointed the water wasn't deeper than it looked.

I'm in, and maybe "The Boss of Me" too. Still kicking myself for not making last year. Thanks for all your work on this Fred.

Good find Lou, Of course some sell for $400, except the one that is my color which is $600. But the add says "fiberglass reinforced." Does anyone know, are the newer ones fiberglass reinforced or do they have the metal plate on the bottom like my recall replacement unit does? Thanks in advance.

Catiadan, I love forensics! I'll share the shipping costs to my house in CT so I can do a photo tear down with fault analysis and post it up to the forum. You in? Bob

Thanks Oakley for posting this. It made me go look at my recalled trunk and guess what! Mine is also cracked. The base plate and the SS reinforcing plate is fine but the trunk plastic is cracking around/near the SS plate. Mine is a 2006 so I doubt they will do much of anything?

The black powder method is only preferred when, after the compression test you want the head "Off" for valve adjustments. :)