89 klr650 w starting troubles... Until a few weeks ago I never had an issue but since then the starter motor will occasionally not turn.
Have read many of the other threads and not finding a solution thus far.
I think the starter motor itself may be bad, but not certain & looking for further guidance
Symptoms / Testing to date:
-Press start button, starter relay clicks, nothing more happens, & starter does not turn.
-Disconnect power leads to starter relay, press & hold start button, starter relay clicks, & reading 2ohms resistance across starter relay terminals & infinite resistance once start button is released
-Replaced stock starter relay with DB Electrical 240-58019
& no change, identical symptoms as listed above.
-Swapped in spare/OEM Starter Circuit Relay & no change.
-With the kill switch in ON position I can roll down a hill, drop clutch and bump start the engine no problem.
-With the kill switch in ON position I can jump starter relay terminals with a pliers, & starter will turn & engine will run.
-Clutch, side stand & neutral safety switches are all bypassed (previously bike would start in gear w/ clutch out & side stand down.)
To Do items:
-clean contacts on kill switch & starter switch (although bike runs otherwise & starter button causes firm click to starter relay)
-bypass starter circuit relay (i can try this, but since I already swapped in an oem spare starter circuit relay & the starter relay itself is closing, this doesn't seem like the issue)
-check voltage between starter circuit relay & starter relay while starter button is pressed (maybe i'm not getting enough volts from the starter circuit relay to fully close the starter relay)
-check/replace starter motor brushes (maybe the starter motor itself is going bad.. its an 89 w/ ~25-30k miles)
-replace starter motor all together (DB Electrical SMU0121
-install the kickstart parts off a klr600 lower end that i've been sitting on for about a year
Any ideas on how to get this thing back to normal?
Thanks in advance!