An interesting problem - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

  • 1 Post By pdwestman
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post #1 of 6 Old 07-16-2019, 10:26 AM Thread Starter
Join Date: Jul 2019
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An interesting problem

I have an issue I have never seen before and can not find an answer to. If it if going on with my bike it has to have happened to at least one other person. I have a Gen1, 07, with 8,000 miles on it. I bought it at 6k and the p/o told me it had a quirk. I forgot about it and then the quirk happened. At random times the bike will shut off like someone turned off the ignition. There are times when I turn on the key and hit the starter button and nothing happens. Every other function works. Here is the crazy part.... beep the horn and it will start???? I just can't figure what the horn has to do the starter circuit. So now if I go with a group I tell them that if they hear the horn beep it's because the starter won't go. Other than that it runs perfect?

Starter won't go, beep the horn go figure


btw. I have been a mechanic and worked on everything from aircraft to motorcycles for 30 years and never seen this.
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post #2 of 6 Old 07-16-2019, 11:06 AM
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From your description . . . I'd look at the starting circuit relay, its wiring/connections (including the starter button switch).

I think the fan relay is an identical part; you might substitute as a diagnostic procedure . . .

(Maybe not; if I'm in error about identical relays mentioned, pdwestman or someone correct me (didn't check the manual before I posted!)) Regardless, I think the Generation 1 has two identical relays.

Then . . . the safety switch logic matrix may be malfunctioning; the kill switch as well.


About your user name, "Ryanpilot." Flew some as a passenger in a Ryan Navion . . . some years ago! Know the aircraft?

“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; 07-16-2019 at 11:12 AM.
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post #3 of 6 Old 07-16-2019, 02:38 PM
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What happens if you turn the front forks? Anything different or no effect?

“Take the risk of thinking for yourself , much more happiness , truth, beauty, and wisdom will come to you that way.” Hitchens
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post #4 of 6 Old 07-16-2019, 07:13 PM
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The horn is mounted very near the starter circuit relay (both on the coolant reservoir bracket), could it be possible that horn vibrations could jiggle the starter circuit magnetic relay just enough to allow it to move freely?
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post #5 of 6 Old 07-17-2019, 11:41 AM
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The first thing I would tell the unfortunate folks that bought the Vulcan 750 over in that forum wsa to CLEAN THE IGNITION switch. There is a "puck" underneath the key that has ball bearings in it that move across contacts when you turn the key. The contacts get corroded and the balls and springs get dirty and stick and electrical systems do crazy things. Also the ground on the battery being loose can do super funky things at odd times. Usually the tach jumps around with ground problems.
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post #6 of 6 Old 07-24-2019, 05:37 PM Thread Starter
Join Date: Jul 2019
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Thanks guys.....

Toney, I could flip the bike over and would not make a difference. The only thing is honking the horn.

pdwestman, you have the closest thing I could think of to an answer, I will check it.

Not a ground issue. I have been through all connections before I posted.
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