2002 KLR650 15,000 miles, Electrical problem starting - Page 3 - 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 #21 of 35 Old 06-19-2019, 10:20 PM Thread Starter
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oh yeah I forgot to mention I have not installed the new relays I just got because it’s starting now. I figured it must not be either one of those.
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post #22 of 35 Old 06-19-2019, 10:24 PM Thread Starter
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I guess the video didn’t work that I posted f my test? Can we post videos?
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post #23 of 35 Old 06-19-2019, 11:40 PM
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You can post videos if they are hosted on YouTube, Vimeo, or some other hosting website.

Relay contacts can go bad and they can be intermittent before total failure. If you've got them, swap them in. It might help and they'll do you no good sitting in a drawer.

Do you know how old your battery is?

Tom [email protected]

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Sting like a butterfly.
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post #24 of 35 Old 06-20-2019, 07:34 AM Thread Starter
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Tom, Thank you for all the great advice! I think I just needed some moral support from a person who knows more than I do. Much appreciated
Quote:
Originally Posted by Tom Schmitz View Post
You can post videos if they are hosted on YouTube, Vimeo, or some other hosting website.

Relay contacts can go bad and they can be intermittent before total failure. If you've got them, swap them in. It might help and they'll do you no good sitting in a drawer.

Do you know how old your battery is?
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post #25 of 35 Old 06-20-2019, 07:37 AM Thread Starter
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I just got a service manual from a friend that will help me a ton. Wish I would have purchased that first! Is the Clymer manual the better one to buy?
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post #26 of 35 Old 06-20-2019, 07:42 AM
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The Clymer manual for Generation 1s stands alone; the Kawasaki service manuals for the same vintage comes in two parts; KLR600 "base" manual, and KLR650 supplement.

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #27 of 35 Old 06-20-2019, 10:50 AM
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Quote:
Originally Posted by Dennis Wallace View Post
I posted this problem in another thread so if that’s a bad thing please delete one of them. I was excited to get some help and thought that this was probably the wrong thread to post my issue on. Link to the other thread is 2002 KLR650 15,000 miles, Electrical problem starting
I used a Forum tool that I haven’t a lot of experience with to Merge the two threads. Results weren’t exactly what I expected. Seems the merge doesn’t look at dates. Unfortunately can’t go back so I hope I haven’t created too much confusion.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #28 of 35 Old 06-20-2019, 10:56 AM
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If it happens that it won’t start again, hook up a booster battery and see if that works. That’s what finally convinced me to replace my Goldwing battery. And that was after I removed the alternator and had it in pieces on the bench.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #29 of 35 Old 06-30-2019, 12:32 AM Thread Starter
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I replaced start circuit relay and solenoid load tested the battery. Thought it was fixed so I put it back together. Started up without problems until I rode it around the no start again. Press the start button and nothing except a sizzling sound down by relay. Today I took it apart again and believe I found the culprit! See pictures attached, the last pic shows the spot it was arcing against the frame. I will have it back together early Sunday and ready for trail riding. So happy I found it
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File Type: jpg C2047B84-87D0-4D13-A27C-F1F2F131F9E3_1561872528426.jpg (147.6 KB, 8 views)
File Type: jpg BDC3B0DE-840A-45AC-BE64-4A691A918112_1561872551658.jpg (362.0 KB, 8 views)
File Type: jpg ADFDF33F-EE59-4A19-A81B-AED152B99D53_1561872574760.jpg (335.2 KB, 9 views)
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post #30 of 35 Old 06-30-2019, 09:05 AM Thread Starter
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Guys, Thanks for your support on this, sometimes all we need is moral support. You all kept me looking. I appreciate that! I posted the problem I found with tree pictures because I wanted to potentially help someone else with similar symptoms. I’m sure you all like to see what the problem actually was. Thanks again! Dennis
PS lesson learned was for me to go with my gut, I was right from the beginning. I just didn’t know it was possible to hear the arcing against the frame like that (sizzling/buzzing sound). It sounded like it was coming from the area around the start circuit relay. It was in fact coming from a yellow/Red wire under the right side front fairing. The other indicators was the start button spring had been hot and I had the stretch it back out. The headlight and instrument panel lights also dimmed when you pressed the start button.
Quote:
Originally Posted by Tom Schmitz View Post
You can post videos if they are hosted on YouTube, Vimeo, or some other hosting website.

Relay contacts can go bad and they can be intermittent before total failure. If you've got them, swap them in. It might help and they'll do you no good sitting in a drawer.

Do you know how old your battery is?
Quote:
Originally Posted by Damocles View Post
The Clymer manual for Generation 1s stands alone; the Kawasaki service manuals for the same vintage comes in two parts; KLR600 "base" manual, and KLR650 supplement.

Last edited by Dennis Wallace; 06-30-2019 at 09:17 AM.
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