Surging/slipping and a kickstand issue - Kawasaki KLR 650 Forum
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post #1 of 7 Old 06-26-2017, 07:10 PM Thread Starter
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Surging/slipping and a kickstand issue

Hey guys and girls,
I've got a couple of issues, which maybe related, maybe not, I've done lots of searching and haven't quite been able to pin point it....
It's a 2012 with just 12000kms.
The first is that I'm occasionally getting an aggressive surge or slip sometime when at 60-90 kph ish, almost as if it's cutting out and the clutch is quickly disengaging engaging. It's only for a split second but fairly aggressive. It makes all sorts of noise through my chain for this split second, maybe just as it's all so sudden.
It's getting more regular, a few times a day rather than once a week.
It seems to happen more reliably when i "hold"at a rev like 4500+ for a while. Climbing a hill or under load with another passenger.
Due to it being more predictable, I've tried to watch the speedo. It does seem to jump higher a touch, when this happens. And then lower as I've lost a touch of speed.
I've made sure that I'm not tapping the gear lever with my foot. And clutch is properly adjusted. I've also taken the valves out of the fuel cap. I've checked the chain tension.

The second is that when pulling to a stop, and putting her in neutral, then putting the kickstand down, the bike instantly cuts out. Sometimes. If I deliberately slam it down, it's more likely to cut out. I can't really get my head around why/how this could happen in neutral.
This has only been happening recently, much later than when the surging started.

So maybe two aren't related, or maybe there's an electrical issue?

Any help or thoughts on where to start would be much appreciated. I'd be happy to take it to an experienced mechanic, but without him being able to reliably make the surge happen, I'm worried that he'll spend a lot of time and plenty of misses trying to get to the bottom of it himself, sounding expensive.

Cheers
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post #2 of 7 Old 06-26-2017, 09:12 PM
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Check your chain and sprockets. Both sprockets. It could be jumping a tooth.

How many miles are on it?

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post #3 of 7 Old 06-27-2017, 09:58 AM
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"The second is that when pulling to a stop, and putting her in neutral, then putting the kickstand down, the bike instantly cuts out. Sometimes. If I deliberately slam it down, it's more likely to cut out. I can't really get my head around why/how this could happen in neutral."

Check to see if the neutral light on the dash comes on in neutral. If not, the switch in the transmission is probably bad.

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post #4 of 7 Old 06-27-2017, 10:21 AM Thread Starter
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Quote:
Originally Posted by Toney View Post
Check your chain and sprockets. Both sprockets. It could be jumping a tooth.

How many miles are on it?
Thanks Toney, It's only done 12000, the sprockets don't look terrible. I've adjusted and readjusted the chain a couple of times, but with no noticeable difference. I've checked for stiff links and can't find anything that seems dodgy. I think I'll take another look though. From what I've read though, it would have to be in pretty obviously bad shape to have such an effect?
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post #5 of 7 Old 06-27-2017, 10:26 AM Thread Starter
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Quote:
Originally Posted by EXBMW View Post
"The second is that when pulling to a stop, and putting her in neutral, then putting the kickstand down, the bike instantly cuts out. Sometimes. If I deliberately slam it down, it's more likely to cut out. I can't really get my head around why/how this could happen in neutral."

Check to see if the neutral light on the dash comes on in neutral. If not, the switch in the transmission is probably bad.
The light is on. Could this switch still be dodgy? Is there any chance the two are related?
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post #6 of 7 Old 06-27-2017, 09:14 PM
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The two are not related. A slip slows the bike and a surge speeds it up a bit. Clutch slippage doesn't make noise, but chain slippage does. Both are more likely to occur under heavy throttle.

There is a switch under a plastic cover at the top of the side stand. That switch sends a ground signal to the ignitor when the stand is up and allows the engine to run, but not when it is down. However the stand switch is bypassed by the neutral switch (concealed by the front sprocket) to allow the engine to run with the stand down when in neutral.

The neutral switch ground signal goes directly to the neutral light, but has to pass through two diodes to signal the ignitor to run. So, a week contact in the neutral switch can allow the neutral light to function, but not the ignitor. A test would be to disconnect the green wire from the neutral switch and ground it. This should keep the neutral light on all the time and allow the engine to run with the stnad down. If it does, you can suspect weak neutral switch contacts or bad diodes.

Last edited by GoMotor; 06-27-2017 at 09:27 PM.
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post #7 of 7 Old 06-28-2017, 01:20 AM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
The two are not related. A slip slows the bike and a surge speeds it up a bit. Clutch slippage doesn't make noise, but chain slippage does. Both are more likely to occur under heavy throttle.

There is a switch under a plastic cover at the top of the side stand. That switch sends a ground signal to the ignitor when the stand is up and allows the engine to run, but not when it is down. However the stand switch is bypassed by the neutral switch (concealed by the front sprocket) to allow the engine to run with the stand down when in neutral.

The neutral switch ground signal goes directly to the neutral light, but has to pass through two diodes to signal the ignitor to run. So, a week contact in the neutral switch can allow the neutral light to function, but not the ignitor. A test would be to disconnect the green wire from the neutral switch and ground it. This should keep the neutral light on all the time and allow the engine to run with the stnad down. If it does, you can suspect weak neutral switch contacts or bad diodes.
Thanks,
I guess I'll need to keep on digging for a chain/sprockets issue. Although the sprockets don't seem to be near their end, maybe it's time to start fresh, with a chain also.
Great info regarding the switches. That makes sense and I can get going from there.
Thanks!!
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