HELP: Engine Won't Turn Over, Now What? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 39 Old 10-13-2006, 11:27 AM Thread Starter
 
Join Date: Jun 2006
Posts: 595
HELP: Engine Won't Turn Over, Now What?

Bike's all back together and I just put in the sealed battery. Checked my cool turn signal switch, oohh'd over the new LED glow in the dash. Crossed my fingers held my breath and hit the starter. *WHIIIRRRRR-ClickClickClick* Hmm... that's odd the piston doesn't sound like it's moving up and down. *WHIIIRRRRR-ClickClickClick* Yep... sounds like the starter is turning nothing.

So, I push the bike up and down the street to a part that's kind of an incline into my driveway. Push it pretty good, hop on and click it down into first gear. *SKKIIDD* the rear wheel just grinds me to a halt. OK, maybe first gear was too tall. I'll try second. Same thing. Third same thing.

I push the bike back into my driveway dismayed, trying to ponder my options. Well, I could just take it to the Stealership since I've got a warranty on it. But what if they find something that gets them out of working on it, and I'm stuck with the shop bill? Or I could drive it to some knowledgable MX wrencher's and we can take the bike apart and see what the problem is, perhaps it's a simple cheap fix.

Any ideas?
Biker Scout is offline  
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post #2 of 39 Old 10-13-2006, 11:42 AM
3rd Gear
 
Join Date: Sep 2006
Location: Franklinville, NC
Posts: 650
Put a wrench on the rotor and try and turn it over by hand.

pull the left cover off and see if something is stuck.

will it (motor) turn over in neutral?

Try turning it clockwise.. and then turn it counterclockwise. does it stop like the piston is hitting a valve?

- Joe

HighSpeed Hiker- DV o5'
Quote:
Originally Posted by larryboy
come awn... it's not far...it'll be fun..

sorry I can't....... I'm fishing today
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post #3 of 39 Old 10-13-2006, 11:51 AM Thread Starter
 
Join Date: Jun 2006
Posts: 595
This was last night at about 11... so any suggestions you guys have I'll have to tinker with this afternoon and weekend. I'll have no answers for you guys until Monday.

Joe, I thought you weren't supposed to turn the motor a certain way? (backwards)
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post #4 of 39 Old 10-13-2006, 11:59 AM
3rd Gear
 
Join Date: Sep 2006
Location: Franklinville, NC
Posts: 650
it's locked up now. whats it gonna hurt?.

I mean dont go trying to make complete revolutions... just a simple backwards and then forwards.

if it dont move either way... your going to have to open it up.

- Joe

HighSpeed Hiker- DV o5'
Quote:
Originally Posted by larryboy
come awn... it's not far...it'll be fun..

sorry I can't....... I'm fishing today
theotherbigjoe is offline  
post #5 of 39 Old 10-13-2006, 12:02 PM Thread Starter
 
Join Date: Jun 2006
Posts: 595
Gotcha! 8)
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post #6 of 39 Old 10-13-2006, 12:07 PM
 
Join Date: Sep 2006
Posts: 102
Did I miss something? Did this lockup follow a mere battery change? Or did you do some other work to the beast?
DSjunky is offline  
post #7 of 39 Old 10-13-2006, 12:10 PM Thread Starter
 
Join Date: Jun 2006
Posts: 595
The battery was the final culminating piece to the puzzle I called my KLR. I had a spill a while back and getting all the bits and pieces took longer than I wanted. Because I replaced nearly everything with the fancy upgraded aftermarket parts.

But to answer your question, I didn't open the engine and make any changes in there.
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post #8 of 39 Old 10-13-2006, 12:14 PM
Neutral
 
Join Date: Oct 2006
Location: Decatur, IL
Posts: 14
Sounds like the starter motor is turning but not engaging. My Clymer manual suggests a worn or damaged starter clutch or damaged teeth on the starter shaft or gears. I would think that if you had damaged teeth you would hear some clattering. I would suspect the other.

The starter clutch is mounted on the back of the rotor and the starter gears and rotor have to be removed to get to it.
It says here "If troubleshooting the starter clutch, the clutch can be checked for freewheel and lockup without removing the rotor. Turn the clutch gear clockwise. The gear should turn freely and smoothly in that diretion. Attempt to turn the gear counterclockwise. The gear should not turn". If it turns both directions or is always locked up, then that's your problem.
Good luck.

03 KLR650
04 CRF250R
Motorized pedalcycle
Spiderman is offline  
post #9 of 39 Old 10-13-2006, 12:21 PM
 
Join Date: Sep 2006
Posts: 143
It has the sounds of an undercharged battery
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post #10 of 39 Old 10-13-2006, 12:25 PM
 
Join Date: Sep 2006
Posts: 102
Quote:
Originally Posted by ham!
It has the sounds of an undercharged battery
Yep...
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