Kick Start; there he goes again... - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

 69Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 249 Old 11-12-2016, 04:31 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 5,787
Kick Start; there he goes again...

I'm going to have another go at it. It's Jeff's fault. I was over it. He was the one who had to come back with that whole spiel about "putting my Gen 2 away, dead battery, cranks so slow, yadda yadda stuff".

A couple of parts have to come from Partzilla first, so in the meantime we'll play with the igniter. Since Denso can't and Kawasaki won't, I'm left to my own state of confusion to try and sort things out.

"And there he goes, swinging a dead cat around by the tail," Tom said curiously.

Here's the pinout for the igniter with a rough idea of where the wires go. edit, updated image


Tom

Tom

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte


Sting like a butterfly.

PPMC #5

Last edited by Tom Schmitz; 11-12-2016 at 11:45 PM.
Tom Schmitz is offline  
Sponsored Links
Advertisement
 
post #2 of 249 Old 11-12-2016, 08:13 PM
General
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 2,790
Tom,
I thought maybe you had Sold the mechanical parts already, No?

3 Cheers for Tom!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.
pdwestman is offline  
post #3 of 249 Old 11-12-2016, 08:50 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 5,787
Paul,

I did sell one set. I need the stopper plate and the gear-disengager to comlete the set I have. I also ordered up some extra clips and thrust washers. The stopper plate is available. For the gear disengager I'm going to modify a KX500 item. I also ordered a new kick lever return spring because they can get a bit weak and I don't know the history of the one I have. Looks good, but...

There was a complete low-mileage set-up for sale the other day and it was located up in Crockett, CA. Just missed out on it by asking questions rather than pulling the trigger. No biggie, as I do have the stuff, though my basket is a bit notched. The seller and I started a long-running conversation on the FB chat thing, so that was nice.

Now, to infinity and beyond!

I took one of my igniters and started checking from pin to pin to see where there might be circuitry in the thing. When doing this, there are two ways to check from one pin to another. Say we are checking from pin 1 to pin 5. It should be checked with the negative lead of the ohmmeter on pin 1 and the positive lead on pin 5, then they should be switched around. You'll see why in a second.

This is the baseline data:


What this tells us is that there doesn't seem to be any circuitry associated with pins 3, 4, 6, 7, 10 and 11. I need to change my graphic to note that. Since there is circuitry associated with pins 5 and 9 (even though Kawasaki put a wire on 9 that isn't on the schematic) one might conclude that Kawasaki chose an off-the-shelf Denso item to use on the KLR. The connectors are standard Furukawa header and female connectors; nothing special about them. This exact series of connectors is readily available in 4, 6, 8, and 16 pin configurations.

Pins 8 and 16 appear to have a diode at the pin, because they don't measure the same in both directions. When we switch the leads on the ohmmeter around, the way we go against the diode shows up as infinity.

Pins 1, 5, 9, and 15 have direct connectivity to one another; not surprising as pins 9 and 15 are grounds and pin 1 must be the grounded side of the crank sensor.

Here's a simplified version with the non-active pins removed.


Now, beyond the above, all of this is about as useful as boobs on a boar. It doesn't tell us anything about the functionality of the unit.

Special thanks to Jeff for being Jeff and to Mr. Phair for teaching me about black box analysis in the sixth grade (what the hell were you thinking?).

Tom

Tom

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte


Sting like a butterfly.

PPMC #5

Last edited by Tom Schmitz; 11-12-2016 at 11:56 PM.
Tom Schmitz is offline  
 
post #4 of 249 Old 11-12-2016, 10:24 PM
General
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,132
Alright!!! I AM IN!!!
I have absolutely no background in electronics but I do have an as yet uninstalled kickstart setup(from Tom 2yrs ago) and both a gen1 and gen2 as a possible home for it. Ironically the gen1's nearly new battery committed suicide this summer, so the gen1 is non running. Let me know if there is anything I can do to help Tom.
Restating the questions:
1)Why can't you kickstart a gen2 ?
2)Why can you push start a gen2 but not kickstart one?
3).....Why can you start one on the battery with it barely turning over, but can't kick it?
JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!

Last edited by justjeff; 11-13-2016 at 12:47 AM.
justjeff is offline  
post #5 of 249 Old 11-12-2016, 11:55 PM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 5,787
3) Why can you start one on the battery with it barely turning over, but can't kick it?

Glad you're in , Jeff!

I need to do some planning, though.

What if I put the kick-starter in and it works? Jeez, that would be embarrassing! What should I do? Fake my own kidnapping? Move to Egypt or or the Basque region?

Partzilla is probably about a week out. I owe a shout-out to Spike613 for the idea of looking for other bikes that use the same stopper and grabbing the gear-disengager from that bike. Turns out you can still get the one from the KX500. I'll see if it can be modified to work. Spike sort of faded away on us; he was going to try it, too.

Tom
justjeff likes this.

Tom

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte


Sting like a butterfly.

PPMC #5
Tom Schmitz is offline  
post #6 of 249 Old 11-13-2016, 12:49 AM
General
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,132
Damn! Now for sure I have to move my gen2 back out of winter storage....JJ
What type of ignition system does the KX500 have?

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!

Last edited by justjeff; 11-13-2016 at 12:53 AM.
justjeff is offline  
post #7 of 249 Old 11-13-2016, 01:02 AM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 5,787
No clue about the KX500. I think they quit making them over 10 years ago.

Tom

Tom

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte


Sting like a butterfly.

PPMC #5
Tom Schmitz is offline  
post #8 of 249 Old 11-14-2016, 11:28 AM
Commander
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 732
I have nothing to add......but I'm watching.... ;-)


LOL,
Cheers,
Dave
pdwestman and round_i like this.
DPelletier is offline  
post #9 of 249 Old 11-14-2016, 11:45 AM
General
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,132
"Well that seems somewhat creepy....Can we ban him Tom?", Whispered Jeff quietly.
DPelletier likes this.

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
justjeff is offline  
post #10 of 249 Old 11-14-2016, 11:57 AM Thread Starter
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 5,787
Nah, he knows too much.

I got an update from Partzilla. The longest lead item will be available to them on Thursday, so I might see stuff by mid next week or so.

The KLR needs to accumulate another 100 miles so I can drop the oil and send in a break-in oil analysis.

Then I can pull side covers and install the fresh inner cover on the left side and the kick-start on the right side.

The clutch cover has been modded for 100% oil filtration. I've done that mode three times now; almost got it down to about 15 minutes of work plus 24 hours of cure time.

I don't know what to do with the ingiter to learn more. Open to suggestions. I could power it up and see what signals I get. Have to think about that. That's outside of the realm of what Mr. Phair taught me in the sixth grade and getting into what Ferd Burns taught me about systems engineering. He was a crusty bastard, but he went to China with Nixon, so there's that...

Tom
round_i likes this.

Tom

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte


Sting like a butterfly.

PPMC #5

Last edited by Tom Schmitz; 11-14-2016 at 12:04 PM.
Tom Schmitz is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Kick starter peter650 2008+ KLR650 Wrenching & Mod Questions 159 11-04-2016 06:46 AM
Need lowered Kick Stand robocop Gadgets & Gizmos 10 06-06-2014 06:52 PM
Kick starter Dave0430 1987 to 2007 Wrenching & Mods 14 10-06-2013 09:10 PM
Did Klr ever come with kick start? Blueklr2008 KLR & Other Motorcycle Related Discussion 6 10-23-2010 12:58 AM
unique ? re Kick start on newer KLRs dougiequick 1987 to 2007 Wrenching & Mods 0 06-22-2007 07:13 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome