Starting problems and extra pieces..... - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 16 Old 03-14-2011, 09:39 PM Thread Starter
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Starting problems and extra pieces.....

OK, my '08 was having problems starting. I hit the button, it makes a growling noise but the engine is not spinning over. I look through the top inspection port on the left side and the mag rotor is not spinning. I pull the left cover off. The starter is spinning but the "starter idle gear limiter" is slipping (back gear is spinning from the starter turning it, front gear is not spinning). I realize I need a new one.

Upon further inspection if the inside, I find very thin wire pieces stuck to the rotor and magnetic pick up sensor inside the cover. The pieces look like a spring but they're not the doohickey spring. The doo is very much intact. These pieces are WAY smaller. The loops are .250" (+/-) in dia., the wire is .012" dia. Could these be springs out of the Starter Idle Gear Limiter? Maybe a roller clutch of some type with springs and rollers similar to a one way "Bendix" clutch?

I have a new limiter on the way, just don't want to go through this again.

BTW, the doohickey spring has good tension (gaps between the coils) and pulls the doohickey to the left smartly when pryed over and released.

Has anyone else out there had problems with the starter idle gear limiter slipping? Common or uncommon problem?

Any ideas out there? Please let me know!

Slim40
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post #2 of 16 Old 03-14-2011, 10:17 PM
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Wire pieces

Sounds like you're on the right track. Pull the rotor along with everything else. There's a one-way in the large gear too. Slippage is prob due to damage already caused. Oil change when you're done. Patience...
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post #3 of 16 Old 03-14-2011, 10:38 PM
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I'm stumped on the origin of the spring-like material. I would be investing in a magnetic oil drain plug....

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post #4 of 16 Old 03-15-2011, 09:53 AM
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I faintly remember reading of a problem such as yours in another forum and can't find it to pass along. It was that one of these gears was allowed to run too far into the bores of the sidecase causing disengagement. The fix was to put a piece of teflon into the bottom of the bore relocating the gear where it needs to be. If the sidecase is chewed up here that is likely the source of the debris found.





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post #5 of 16 Old 03-15-2011, 08:31 PM Thread Starter
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Thanks Flash for the reply.

Thanks Flash for the reply. I don't think this is the problem I have. The gears are in alignment with one another. The debris I found is steel (stuck to magnet) and was uniform in diameter. They were not aluminum shavings and I found no damage to the inside of the case.

The "starter idle gear limiter" is a multi-piece unit (not machined from one solid piece). It appears that the back gear that engages the starter shaft has an inner, seperate piece. Looks like the outer piece with the gear teeth is pressed onto this inner part with something in between the two. This appears to be where the slippage is occuring.

As I noted, I have a new unit on the way. For $106 + shipping, I want to make sure I get it right the first time. Don't want to go through this again.

I will post my findings after the new unit is installed. I am curious enough that I will disassemble the old unit to see what and how it works. May involve some level of distructive disassembly!

Thanks for your input!

Slim40
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post #6 of 16 Old 03-16-2011, 07:03 PM
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Sorry, too much time on my hands and too much coffee plus I'm staying at a Holiday Inn and feeling really smart. I see now, it's a sprag clutch to the rest of the world.

Post up some pics of the new and old ones. It would be interesting to see and possibly know why it failed.
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post #7 of 16 Old 03-23-2011, 09:12 PM Thread Starter
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Dr. Frankenstein, IT LIVES!

Got the new starter idler gear limiter via the Big Brown Bus. Drained oil, pulled cover, replaced gear, put it all back together, poured oil in and VIOLA'! It starts like it's supposed to!

Put the old unit in the vise and gripped one of the gears with a pair if large channel locks and it slips/spins MUCH easier that I would have thought. Not sure if it is supposed to spin at all or not. Don't have time tonight but plan to disassemble this in the next few days and let you know what's inside.

All for now....
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post #8 of 16 Old 03-27-2011, 08:41 PM Thread Starter
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OK, here's the pics of the "limiter"!

I tried to pull the starter gear off with a gear puller, nuthin' doin'! Out comes the cut off wheel and sparks fly. Here's what I found. The gear that is engaged with the starter fits over a tapered race that has a sleeve in between. There are some wavy washer springs down between the gears, I suppose that these keep the starter gear pushed up on the taper to create the friction fit.

I have also included a pic of the spring wire pieces I found inside. I never found any other pieces even during the second case removal to install the new limiter.

Any ideas?

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post #9 of 16 Old 04-07-2011, 09:30 PM Thread Starter
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Could these pieces be.....

the spring from the KACR (auto compression release)? I've noticed that when the engine is cold, it will crank for a second then hesitate like a compression lock. It will then continue to crank and start normally. It does not do this when the engine is warm. I'm wondering if the KACR is not releasing the compression like it should. By the pic in my Clymer manual, the spring on the KACR appears to be the same approximate size of the pieces I found.

I know I will need to remove the cam cover to check this. I will probably do so this coming weekend.

Has anyone had an issue with the spring on the KACR breaking and/or coming apart?

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post #10 of 16 Old 04-07-2011, 10:42 PM
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The KACR is on the opposite side of the motor so it would have to do some serious migration to get to the starter gear.
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