Start button does nothing - 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 12 Old 06-09-2018, 03:27 PM Thread Starter
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Start button does nothing

Hello fellow KLR lovers. I have a 2009 that has only about 5500 miles on it, bought less than a year ago with 4500 on the OD and have been loving this thing any chance I get. I definitely have the dualsport bug. Last Saturday a SUV pulled out in front of me on a twisty backroad and had to lay the bike down to avoid a T-bone. It was low speed so all the important stuff is fine, busted up all the plastics in the headlight and fairing etc which is why they’re going to total it. I am planning on buying it back and rebuilding it, maybe switch to a Trailtech 8 inch race light and one of their gage systems. The only problem is the bike does nothing when I press the starter button. Where should I start testing? I checked the fuses and all are ok. Is there a relay somewhere I am missing? Could it be the switch itself? Thanks for any help in advance.
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post #2 of 12 Old 06-09-2018, 07:33 PM
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Check the MAIN FUSE under the RED Plastic squeeze connector on Top of the High Amp starter Relay on the left side of the bike. The Spare Fuse is just tucked into the rubber holster at the bottom of the relay!

Chances are high that there is wire damage at the right front of the gas tank!

pdwestman
Modify at "YOUR OWN RISK"!

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post #3 of 12 Old 06-09-2018, 09:34 PM
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Start issue

Do you have power to lights? Check battery connection?

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2017 Yamaha XT250
1990 Honda NX250 (Green/White)
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post #4 of 12 Old 06-10-2018, 07:57 AM Thread Starter
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I checked the main fuse, it’s in good shape. There is no obvious damage to the wiring harness up front. The way I could most accurately describe it is if the kill switch was off or the kickstand down and in gear. Just no response at all on the start button. Not even a click.
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post #5 of 12 Old 06-10-2018, 08:09 AM Thread Starter
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My headlights are smashed so no headlights, but the indicator lights etc in the dash work fine. I get the neutral light which makes me think it isn’t related to a neutral lockout or something like that.
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post #6 of 12 Old 06-10-2018, 10:39 AM
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Your starter CIRCUIT relay needs fulfillment of safety switch logic to close its contact; STARTER relay (inaccurately called the "solenoid," by some) cannot actuate unless the starter CIRCUIT relay is activated.

With a multi-meter and a wiring diagram (available on the 'Net), you can chase wiring continuity and voltages to diagnose (and fix) your problem.

The starter button sends + 12 VDC through the starter CIRCUIT relay contacts to the STARTER relay. Somehow, this chain appears interrupted with your bike.
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post #7 of 12 Old 06-10-2018, 12:15 PM
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The diode pack which contains the three diodes fed by the three safety switches (neural, clutch and side stand) is behind the dash near the headlight housing. If the light is messed up the diode pack or the wiring to/from it may be also. If no signal gets through this pack, the starter will not operate and the ignition will not fire the plug.
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post #8 of 12 Old 06-10-2018, 12:28 PM
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Quote:
Originally Posted by GoMotor View Post
The diode pack which contains the three diodes fed by the three safety switches (neural, clutch and side stand) is behind the dash near the headlight housing. If the light is messed up the diode pack or the wiring to/from it may be also. If no signal gets through this pack, the starter will not operate and the ignition will not fire the plug.
Quite so. If the safety switch logic isn't fulfilled, the starter CIRCUIT relay has no ground and cannot be activated; thus, no control voltage activates the STARTER relay.

Could the safety switch circuitry (including the starter CIRCUIT relay) be bypassed entirely, with the + 12 VDC OUT of the starter button switch wired directly to the small control voltage terminal of the STARTER relay? Probably!
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post #9 of 12 Old 06-10-2018, 12:47 PM Thread Starter
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Thanks so much, I’ll try to measure these things out although I have to admit I’m not the most proficient with a multimeter. I think you’re likely right on it’s the diode pack or the relay, since the turn signal relay was broken out of the bike entirely and the big grey plug on the wiring harness that clips into the same place had the clips broken. Would suggest that area saw some damage in the crash even though the diode and starter relays were not displaced. Thanks again and I’ll let you know my progress/any other questions. I really appreciate it.
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post #10 of 12 Old 06-10-2018, 06:16 PM
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Quote:
Originally Posted by Aghutter View Post
Thanks so much, Iíll try to measure these things out although I have to admit Iím not the most proficient with a multimeter. I think youíre likely right on itís the diode pack or the relay, since the turn signal relay was broken out of the bike entirely and the big grey plug on the wiring harness that clips into the same place had the clips broken. Would suggest that area saw some damage in the crash even though the diode and starter relays were not displaced. Thanks again and Iíll let you know my progress/any other questions. I really appreciate it.
Good luck, Aghutter, and remember--the starter CIRCUIT relay and the STARTER relay are two separate and distinctly different animals!
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