Starter freewheeling - 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 15 Old 10-09-2016, 08:15 PM Thread Starter
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Exclamation Starter freewheeling

Started to have starting issues, need help to determine what the problem is. It turns the engine a bit then freewheels. I have my 2008 KLR open to do the doohikey and fix the deep hole. Could it be simple as low battery? I can't test it now that it is open. But if I need to change the starter clutch, now would be a good time. Do you guys think it is the starter clutch? I took it out and there is no apparent damage to any of the parts. the starter gear turns in only one direction as it is supposed to.
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post #2 of 15 Old 10-09-2016, 09:04 PM
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My suggestion is that the 'back-fire' torque limiter has slipped too many times. And now slips on the compression stroke of the engine during cold cranking.

Part #39076-1056 as seen here,2008 Kawasaki KLR650 (KL650E8F) Starter Motor | Babbitts Kawasaki Partshouse

Replace it!
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post #3 of 15 Old 10-10-2016, 10:35 AM
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Learned something new.

How does this part or system work in principle? I didn't look too closely when doing the doo, but I did not know this
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post #4 of 15 Old 10-10-2016, 12:49 PM
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Originally Posted by OkiePokie View Post
Learned something new.

How does this part or system work in principle? I didn't look too closely when doing the doo, but I did not know this
Basically one gear is Only Pressed onto the shaft of the other gear. X amount of interference fit.
So if too much Torque is applied, it slips.

The starter torque limiter gear, starter sprag clutch and the transmission clutch are the main reasons to Not Use automotive engine oils with super slippery additives.

Look for the JASO MA or MA2 on the back labels.
My preferred engine oil is Genuine Kawasaki 10W40 petroleum Motorcycle oil. part# K61021-202A.

And I have the laboratory results to show why.
Read here, http://www.klrforum.com/klr-other-mo...is-thread.html
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post #5 of 15 Old 10-10-2016, 03:00 PM
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Originally Posted by pdwestman View Post
]
Could this by chance also have something to do with the gear being able to slid too far in the cover or case? I don't remember which. But I remember a test from somewhere to determined if there was too much movement due to wrong size stop or no stop on the upper gear if I remember right.
If you can't figure out what I'm talking about, I won't be offended. I'm used to it!!
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post #6 of 15 Old 10-10-2016, 05:58 PM Thread Starter
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I think you are referring to the deep hole issue found on 2008 and some 2009's. I have addressed that issue on my bike, so it's something else. Thanks for the suggestion!


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post #7 of 15 Old 10-10-2016, 06:03 PM Thread Starter
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Originally Posted by pdwestman View Post
My suggestion is that the 'back-fire' torque limiter has slipped too many times. And now slips on the compression stroke of the engine during cold cranking.



Replace it!


When the starter freewheel, all the starter gears, including the big one, spin and the rotor doesn't. From this, I deduct it is the one way clutch. I assume if it was the torque limiter, the largest starter great would not turn?


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post #8 of 15 Old 10-10-2016, 07:52 PM
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Quote:
Originally Posted by Squevill View Post
Started to have starting issues, need help to determine what the problem is. It turns the engine a bit then freewheels. Do you guys think it is the starter clutch? I took it out and there is no apparent damage to any of the parts.

the starter gear turns in only one direction as it is supposed to.
Squevill,
I answered to the best of my knowledge and experience from the info provided.
It could easily be Both! I've seen it on ATV's.
Of course one can Not Actually "see-it"! You have got to put the cover back ON to support the gear shafts to 'Try It'!

Squidly,
The 'Deep Hole' problem is on the Second set of Gears of the starter reduction system. The set with the Coarser Teeth.
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post #9 of 15 Old 10-10-2016, 08:57 PM Thread Starter
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Originally Posted by pdwestman View Post
Squevill,

I answered to the best of my knowledge and experience from the info provided.

It could easily be Both! I've seen it on ATV's.

Of course one can Not Actually "see-it"! You have got to put the cover back ON to support the gear shafts to 'Try It'!



Squidly,

The 'Deep Hole' problem is on the Second set of Gears of the starter reduction system. The set with the Coarser Teeth.


Well, I ran the starter without the cover while supporting both sets of gears. Probably not the best idea but was able to see what was going on.


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post #10 of 15 Old 10-11-2016, 08:15 AM
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Squidly,
The 'Deep Hole' problem is on the Second set of Gears of the starter reduction system. The set with the Coarser Teeth.
That's it! Thanks for the brain bump!
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