2002 KLR650 15,000 miles, Electrical problem starting - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 1Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 35 Old 06-18-2019, 07:32 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
Hi from Sandy Oregon (Mt Hood)

I purchased a 2002 KLR650 with 15,500 miles on it. Can’t wait to get some good riding time. I took it out the day after I purchased it and after a full day of riding forestry roads it would not start! I have been working on it every since. I’m learning a lot but it driving me crazy! HELP NEEDED thanks in advance
Dennis Wallace is offline  
Sponsored Links
Advertisement
 
post #2 of 35 Old 06-18-2019, 07:45 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,195
Welcome to the forum, Dennis.

Do you need to turn the fuel petcock handle forward to Reserve to access the last gallon of gas? Then with no choke & no throttle, crank the starter motor for 20 seconds to fill the carb, pull the choke lever ON while still cranking. Might fire right up.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 83,000+ miles & counting
pdwestman is online now  
post #3 of 35 Old 06-18-2019, 08:09 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
It’s electrical problem and I have spent hours reading online and trying to figure it out. I had to push start the bike to get it home. Luckily I was in a good spot to do that. I have already jumped out the clutch safety and kickstand safety. When you press the start button it would only make a sizzling sound down by the start relay
Dennis Wallace is offline  
 
post #4 of 35 Old 06-18-2019, 08:12 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
It’s like I have a short to ground. I took the start button apart because it was not feeling good (no spring left). I found that it must have got hot so I stretched the spring back out and put it back together
Dennis Wallace is offline  
post #5 of 35 Old 06-18-2019, 08:17 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
After days of working on it I got home from work today and tried a used start circuit relay and it fired up! I was so excited... then I thought that’s to good to be true so I put the old switch back in and it started up again! Damn! I don’t want to be stranded out in the sticks when it decides to happen again. Any ideas?
Dennis Wallace is offline  
post #6 of 35 Old 06-18-2019, 08:26 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
Quote:
Originally Posted by pdwestman View Post
Welcome to the forum, Dennis.

Do you need to turn the fuel petcock handle forward to Reserve to access the last gallon of gas? Then with no choke & no throttle, crank the starter motor for 20 seconds to fill the carb, pull the choke lever ON while still cranking. Might fire right up.
Thanks for the tip on reserve I was wondering how far reserve would take you and how hard to get fuel back into the carb.
Dennis Wallace is offline  
post #7 of 35 Old 06-18-2019, 09:14 PM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
2002 KLR650 15,000 miles, Electrical problem starting

I got 1 full day of riding trails and forestry roads. On the way home I stopped for a cold drink and then it would not start. When I pressed the start button I could hear a sizzling sound down around the starter relay. The headlight and neutral light dims. I was able to push start it with the help of another rider I had just met. Got it home and have been working on it for days. Today I get home and try a used start circuit relay that came in a box of parts with the bike. It started right up! I was excited then I thought that’s to good to be true... I put the old relay back in and it started! I think it’s a wire shorted to ground somewhere? I took the start button apart because it didn’t feel right (no spring left in it). I found the spring had gotten hot so I stretched it back out and put it back together. When I put my meter on the starter relay and pushed the start button I only got 1.6 volts. The battery has 12.8 volts. I also tried to hook jumper wires up to the starter relay and it started right up. I have also jumpered the clutch safety switch and the kickstand switch just to take that out of the equation. Any help or suggestions would be greatly appreciated. I don’t want it to happen again out in the sticks. Thanks
Dennis Wallace is offline  
post #8 of 35 Old 06-18-2019, 09:44 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,168
Bad battery?

Next time you have the same problem, jump your battery with a known "hot" one. If starting easy under that condition . . . likely bad battery.

Sometimes, battery voltage appears sufficient, but . . . under load, one or more battery cells tanks, can't deliver the current needed by the starter motor.

To your advantage, a KLR the age of yours will push-start and run with no battery at all . . .

“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

Last edited by Damocles; 06-18-2019 at 09:47 PM.
Damocles is offline  
post #9 of 35 Old 06-19-2019, 04:05 AM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
Thanks for your advice, I will definitely try that. I wish I had tried that when it first came up. I guess I could take the battery out and have it load tested? Would a bad battery also make the starting circuit heat up? I ask because While the problem existed I jumped the start button thinking it may be bad. When I did, it felt like my jumper wire got hot. The button also did not have much spring back to it. When I took it apart the spring looked like it had been hot. I stretched the spring, cleaned contact and put back together. Jumping the switch did not change anything, headlight dimmed and no start.
Quote:
Originally Posted by Damocles View Post
Bad battery?

Next time you have the same problem, jump your battery with a known "hot" one. If starting easy under that condition . . . likely bad battery.

Sometimes, battery voltage appears sufficient, but . . . under load, one or more battery cells tanks, can't deliver the current needed by the starter motor.

To your advantage, a KLR the age of yours will push-start and run with no battery at all . . .
Dennis Wallace is offline  
post #10 of 35 Old 06-19-2019, 04:10 AM Thread Starter
1st Gear
 
Dennis Wallace's Avatar
 
Join Date: Jun 2019
Location: Sandy, OR
Posts: 36
I know that a bad connection or a short to ground would cause heat in the wiring. Not sure if a bad battery would do the same?
Dennis Wallace is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome