2011 KLR650 died on while driving down the freeway - Kawasaki KLR 650 Forum
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post #1 of 9 Old 10-07-2013, 05:43 PM Thread Starter
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2011 KLR650 died on while driving down the freeway

I have question. I am a new rider of a 2011 KLR 650. It had 3700 miles it on when I got it. I have put about 2000 miles now. I was riding it down the freeway and it died on me. I had Plenty of fuel and the battery seems fine lights are on etc. When I got it home I replaced the spark plug and it started right up. I went to start it up the next day and it wont start. Any Ideas on what I it could be?

Thanks
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post #2 of 9 Old 10-07-2013, 05:49 PM
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I'm not terribly mechanically inclined, so I'm not too sure this advice will help, but check the small hoses that connect to the petcock.

Also, is your bike the black and grey version, and do you perchance have use a white dual sport style helmet? Just asking because I passed a KLR on the side of I-15 near 9000 south on Saturday afternoon...

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post #3 of 9 Old 10-07-2013, 05:52 PM Thread Starter
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Ha ha Yep that was me. Thanks I will check those hoses.
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post #4 of 9 Old 10-07-2013, 05:57 PM
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If I could have stopped, I would have. Unfortunately I was just off the HOV lane and moving along at about 80 mph. There wasn't any way I could have stopped in time to not get blocked by the onramp...

Sorry Dude! If you make it out to Tooele County, I'll buy you a beverage as an apology!


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post #5 of 9 Old 10-08-2013, 01:47 PM
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Here's what just happened to me: The sparkplug cap, which screws directly into the spark plug wire, had come unscrewed a bit, and was keeping the engine from running.

It happened right after I changed the plug. I changed the plug back to the old one, and it started working, but it was only because in doing so, I'd jiggled the cap and wire enough to make contact again.

I snugged the wire to the cap to fix it, i.e. I turned the cap clockwise on the wire until it was lightly snug. (Until the guys here on the forum pointed that out to me, I'd had no idea that could even go wrong.)
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post #6 of 9 Old 10-08-2013, 07:24 PM Thread Starter
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Thanks for the input. I tried that and thought it was the problem because it seemed loose, until I went for a ride and it died on me after 25 miles. It was running perfect and then backfired and stalled out. I got it running after messing with the spark plug wire made it half way home and it died again. It turns over fine but just wont start. Got running again after I got home by messing with the wires. Can a spark plug wire go bad after 5500 miles?
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post #7 of 9 Old 10-08-2013, 07:41 PM
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Quote:
Originally Posted by mckayadventures View Post
Thanks for the input. I tried that and thought it was the problem because it seemed loose, until I went for a ride and it died on me after 25 miles. It was running perfect and then backfired and stalled out. I got it running after messing with the spark plug wire made it half way home and it died again. It turns over fine but just wont start. Got running again after I got home by messing with the wires. Can a spark plug wire go bad after 5500 miles?
It was also speculated that the wire unscrews at the coil end, as well. (Speculated, but not confirmed.) Mine was snug on that side, and I decided I didn't want to risk twisting it around and breaking something. But you could check if it was snug there.

The plug wire sure seems suspect, but maybe someone with more experience than I has another idea.
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post #8 of 9 Old 10-09-2013, 01:58 PM Thread Starter
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I think I fixed my problem. I found that my Fuel tank was wearing a hole into the wiring harness above the horn. There were a few wires that I could see copper showing through. I taped them all up nice and adjusted the wire loom down where there would be less contact and friction. Went for a test ride and so far so good.....
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post #9 of 9 Old 10-09-2013, 05:02 PM
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Quote:
Originally Posted by mckayadventures View Post
Went for a test ride and so far so good.....
Excellent!

There's that place above the horn where two metal tabs hold the harness in place, too. The bolts on that were what wore through mine, shorting out the fan and blowing its fuse. I taped it all back up, filed off the bolt heads so they were less sharp, and wrapped up the harness there in a piece of slit vinyl tubing to protect it. Didn't want that to happen again.
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