Wiring Diagram - 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 16 Old 05-20-2013, 11:05 AM Thread Starter
2nd Gear
 
Join Date: May 2013
Location: Gainesboro, TN
Posts: 114
Wiring Diagram

Found a link to a nice, color coded one but messed up and lost it. Parked the bike yesterday and was gonna ride to get a Clymers today but bike won't turn over. Had my son double check to see if I was overlooking a safety switch. He says, slight click with starter sw. but no crank. Headlight, horn work. If someone will help me find the diagram , I will do my best to not lose it again....

Thanks,

Jim
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post #2 of 16 Old 05-20-2013, 11:09 AM
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Location: Pefferlaw,Ontario
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Take the left side cover off the bike the very small one beside the carb. There is a switch in there for the side stand safety switch....find the two wires and jump them together. Then go to the clutch lever and find the two wires that come out of the switch under the lever, same thing jump those two. That's all there is to it. What year machine is it?

Willys
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post #3 of 16 Old 05-20-2013, 11:10 AM
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If you have done this already and it still isn't working, clean all connections from the battery to the starter, positive and neg.
Spray a little WD40 into the starter switch also to possibly clean the contacts.
The battery is a good one,.... right?

Willys
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post #4 of 16 Old 05-20-2013, 11:20 AM Thread Starter
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Join Date: May 2013
Location: Gainesboro, TN
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Thanks

Haven't gotten to is yet - Battery seems to be good, looking at headlight and horn. Son said "no click with start sw when kill sw is in off pos....Thanks for the tips for when I start. I had the diagram in downloads but must have inadvertently dumped it. Is the color coded one from Clymers?

Jim

It's a '98

Last edited by Jim Sizemore; 05-20-2013 at 11:35 AM. Reason: Answering question
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post #5 of 16 Old 05-20-2013, 11:34 AM
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post #6 of 16 Old 05-20-2013, 11:53 AM Thread Starter
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Join Date: May 2013
Location: Gainesboro, TN
Posts: 114
Again, thanks

That's much more than I was hopeing for! I just read somewhere(but don't ask me where it was) about your Willys - wondered if that was where your handle comes from. My uncle ED had a '39 that I learned (illegally & under aged) to drive in. Was a neat, 4cyl car. I could back up without jerking things but took forever to learn clutch tecqneque(sp?) going forward. Would go all the way around the block in reverse! didn't the hood open from the windshield? MY that was a long time ago. I'll start my 80th yr in Sept(fingers crossed!)

Jim
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post #7 of 16 Old 05-20-2013, 01:28 PM
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Join Date: Jan 2011
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"Slight click" suggests a battery problem, to me.

Lights might work, but . . . battery might not be able to handle the current load of the starter motor.

Modestly-proposed test: JUMP the battery with a connection to a known "hot" battery; e.g., from a running automobile; see if it starts (for those opposing the procedure, "Professional rider, closed course, do not try this at home!" )

Last edited by Damocles; 05-20-2013 at 01:37 PM.
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post #8 of 16 Old 05-20-2013, 03:31 PM Thread Starter
2nd Gear
 
Join Date: May 2013
Location: Gainesboro, TN
Posts: 114
Slight click

Not knowing where the various rrelays are located, I "think" I'm hearing the starter relay and not the starter solenoid. Do any of you folks know of a relay physical location diagram?

I will post findings when I find something....

Jim
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post #9 of 16 Old 05-20-2013, 03:33 PM
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Join Date: Jan 2011
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Don't want to jump it?

Your call, certainly, but . . . just curious: Why not?

Jumping the battery is only for diagnosis; if the starter turns over readily with a known hot battery connected, then--I'd consider a deficient battery the problem.

----------------------

BTW; KLRs have each a "starter circuit relay," and a separate "starter relay;" no "solenoid" engaging starter drivetrain, as with some automobiles.

To find the starter relay, follow the heavy cable from the battery positive terminal to its lug on the starter relay; or--follow the heavy cable from the starter motor to its lug on the starter relay.

Last edited by Damocles; 05-20-2013 at 11:09 PM.
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post #10 of 16 Old 05-21-2013, 08:30 AM Thread Starter
2nd Gear
 
Join Date: May 2013
Location: Gainesboro, TN
Posts: 114
Problem temporarily resolved

My brother listened while I operated the starter button and located, I guess, the start relay just above the kick stand switch? I held the start button in and he poked this relay with his finger - the bike roared to life! Why does this always scare us- when that is what we are trying to accomplish!? IS this the start relay? It's just hanging there, so must have wiggled a conector....Thanks again all, for the tips. Payday, I will hunt a Clymers manual.

Jim
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