Question for the mechanics in the group - 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 8 Old 11-14-2007, 06:47 AM Thread Starter
 
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Question for the mechanics in the group

This morning I packed up my '08 for my 40+ mile commute, cranked it up, let it warm up a minute or so like always and slowly took off down the street. Got about 100 yards and the light went off, then came back an flickered and the bike coughed and sputtered, but never completely cut off. I turned around and nursed it back home. Checked the gas lever, still straight down, just filled up yesterday and have about 50 miles on the current tank of gas. It was dark and I didn't really have time to check a lot more because I had to get in the truck and get to work. I'll call the dealer soon and make an appointment for Saturday, but was just wondering if anyone, either from experience or just superior mechanical ability to me (that includes almost everyone with a pulse) might have an idea of what to check first. I still plan to take it to the shop, but I would like to be able to drive it the 8 miles there as I don't have a really easy way to transport it. It's got about 3200 miles on it, has had the oil changed several times and this is the first sign of trouble. Any ideas? Thanks for your time.
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post #2 of 8 Old 11-14-2007, 07:04 AM
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OK, gonna throw an idea here, if the light went off, it sound electrical of course, I had a problem with my battery getting low on me a few weeks after buying it. You might want to check and put the battery on charge for several hours. Once I did that I had no more problems. Another instance I had a month ago, I had started and road my bike to a friends house with no problem. I went to leave and the bike would not hit a lick. Nothing, no lights, horn, signals, nothing. I pushed it down the road hoping to bump start it, nothing. I finally broke out the tools and took off the seat to check the battery connections and found the main wiring harness to the fuses had come loose from the connection. I pushed the connectors together and heard it click, and the bike fired right up. You might outta check the connections and of course possibly the battery. My lights and nothing else would work with the connector not hooked up. Keep us posted, am curious to know what it is.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 8 Old 11-14-2007, 08:38 AM Thread Starter
 
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Thanks, DX

Now, to further show my ignorance, from your comments I gather the battery is not hooked up to an alternator or generator like an auto? Is there a special battery charger I need to buy for this, or do one of the "trickle" chargers you would use for an auto work on a different setting? Does that bright headlight work solely on battery with no help from the engine? If the battery is the cause of the light going out, would that affect the driving, (sputtering, etc.?)

Told you! Before computers I used to be able to do my own tuneups, oil changes, etc. on my car, but I've never been accused of being Mr. Goodwrench. Thanks for taking the time to reply, it's appreciated.
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post #4 of 8 Old 11-14-2007, 08:50 AM
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the engine uses a stator similar to a lawnmower to produce current and then goes thru a rectifier then to the battery. The bike should run even if the battery is low, but it will NOT run if those connectors under the seat are not connected. Yes I used my automotive battery charger set at 2 amps and or 6 amps and charged my battery for about 5 hours. The Light should run from the stator if the battery is bad. Just to give you an idea. this past Sept. my buddy and I went back down to Tellico area in TN to ride. We were in the middle of nowhere on a dirt road when he started smelling a hot electrical smell. Well after some detective work we found his battery was completely empty of fluid except for one cell that had about two inches of fluid in it. We poured water from one of our water bottles into the battery and started our process of travelling way back over to Robbinsville, NC to a motorcycle shop and got him a new GEL battery. Amazingly the bike ran fine, testament to the stator working good. The battery was toast. I have learned you have to keep an eye on the factory batteries quite a bit as they tend to loose electrolite and need servicing often. I suggest a good gel or dry cell battery. Figure $100 will take care of it for many years of worry free riding. I am sure some other guys in here may have a much better idea of some of your problems, this just happens to be some real life issues I have faced and I feel might be possible areas of concern for you to look at. I hope this helps some. Oh..lol..grab a couple extra battery cable bolts. We lost one of his while working on the battery and had to resort to a cable tie to hold the negative cable to the battery till we got back to the bike shop. You always think your prepared, but something will pop up and Murphy will bite you...well he does me anyway...good luck with your issue. I don't think it will be anything major.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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Last edited by DXKLR; 11-14-2007 at 08:52 AM.
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post #5 of 8 Old 11-23-2007, 10:19 AM Thread Starter
 
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DX,

You asked me to keep you posted as to the problem. I called the dealership and they suggested I bring it in. Since it's still under warranty, I got it loaded into the truck and took it in last Saturday. Turns out it was a wire in the battery harness (as you suggested), but it wasn't loose, it was rubbing on some metal and finally rubbed enough to short out. They fixed it, no charge, and I rode it home, so all's well. I do wonder, however, if it was an assembly defect, or results of the time a couple of months ago that I dropped it. At any rate, thanks for your wisdom.
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post #6 of 8 Old 11-23-2007, 11:05 AM
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There have been several reports of 08's with poorly routed wiring getting chaffed until it shorts out. Glad ya got it fixed.
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post #7 of 8 Old 11-23-2007, 05:00 PM
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As I sit here at work reading this post I are gonna go out and pull my bike inside the shop and start checkin this stuff out, damn human error anyways...

I used to be twice as fast and half as good, now I am twice as good and half as fast, gettin older not such a bad thing...
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post #8 of 8 Old 11-23-2007, 08:20 PM
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Well to add to the electrical 08 mysteries, my buddies new 08 turn signal indicator on the dash has quit working. 50 miles on the odometer. We rolled it outside day before yesterday for our ride and it wouldn't start. Took the side panels and seat off, and the battery cable fasteners were LOOSE!!.. Tightened em back up and it fired right up. The turn signal indicator worked then also, but by the time we got back home it had quit again. He is going to take it to the dealer and let them deal with the headache of tracking it down.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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