Ignition problem?? - 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 3 Old 12-13-2007, 12:53 PM Thread Starter
Join Date: Aug 2007
Posts: 5
Ignition problem??

I have a 98 KLR. Occasionally when I attempt to start my bike I will see some smoke come out from under the right side of fuel tank area. The smoke has a burning electrical smell. The bike still cranks over fine when this happens. I live in Nebraska so I havent riden the bike for a couple months. Last night I wanted to start it up and run it for a couple minutes and of course it took quite a bit of cranking to get it going. When I initially started cranking it started smoking pretty good. I kept cranking for a little bit (I know I probably shouldnt have) and it finally stopped cranking and the green nuetral indicator light shut off, but the headlight stayed on. At that point I figured I had probably fried somthing, so I removed the seat and fuel tank to do a visual inspection. I didnt see any wires fried so after letting it sit for about 20 minutes I went ahead and tried to crank it over again. As soon as I turned the key back on the green neutral indicator came on and it cranked fine and there was no smoke this time. The bike finally started and everything was ok. I am assuming there is probably a smoked relay or maybe the ignition switch is getting cooked, but I dont exactly know what I'm looking for. Of course I am a little concerned about this, I am wondering if anyone out there has seen this before or might know what I can do to fix somthing like this? I would really appreiciate any input.
P.S.- Somthing else I have noticed that may or may not have anything to do with it is the start button assembly where is attaches to the handle bar is a little loose and somtimes it almost seems that if I kind of hold onto the back of the switch when I push the button then it wont smoke, but that could just be a coincidence.
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post #2 of 3 Old 12-13-2007, 07:31 PM
Join Date: Aug 2007
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I think both issues MAY be connected. take a look into it and see. anything that smokes should be looked at ASAP
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post #3 of 3 Old 12-13-2007, 08:57 PM
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Join Date: Sep 2006
Location: Paso Robles, CA.
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Follow the wires from the starter and look for any chaffed wires. You will need to undo any wire ties so that you can get a good look at the wires. I'm sure you'll find one the is rubbing the frame somewhere. Good luck.
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