Starter troubles - 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 09-21-2018, 02:44 PM Thread Starter
1st Gear
 
Join Date: Aug 2016
Location: Earth, Terran System
Posts: 24
Starter troubles

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

What else?

Any ideas on how to get this thing back to normal?

Thanks in advance!

Last edited by slackard; 09-21-2018 at 03:24 PM.
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post #2 of 3 Old 09-21-2018, 07:48 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,537
So if I understand correctly you have substituted both the low amp relay and the High Amp Relay? And when you jump across the High Amp relay terminals the starter will crank and if the key is on, it will start?

I would try to catch the starter in a 'dead-zone'. Then hold the button down & use a screwdriver handle to tap on the starter end cap to see if worn starter brushes could be the issue.

But, my 1987 has 82,000 plus miles on its original parts (including brushes), but I do live in a dry climate.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 3 Old 09-22-2018, 09:20 PM Thread Starter
1st Gear
 
Join Date: Aug 2016
Location: Earth, Terran System
Posts: 24
Quote:
Originally Posted by pdwestman View Post
So if I understand correctly you have substituted both the low amp relay and the High Amp Relay? And when you jump across the High Amp relay terminals the starter will crank and if the key is on, it will start?
Correct on all points.

Swapped the high amp relay for an OEM spare, as well as the DB Electrical 240-58019 with identical result.

Also swapped in an OEM / Spare low amp relay with identical result across the board.

When removed from the bike, all 3 high amp relays show the same resistance (~2ohms when closed, & infinite when open) using an external 12v power supply to close the relays.

I will try the deadzone test you mentioned to see about the starter brushes... makes sense..

The bike was stored outdoors this summer.. always under a tarp, but it saw more moisture than it's probably used to

Will report back with results....

Thanks!
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