Dead KLR - 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 19 Old 08-23-2019, 06:19 AM Thread Starter
2nd Gear
 
Join Date: Jun 2018
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Turned on the key on my ‘14 KLR with 15k miles this morning then hit the starter button. Heard a split second noise then everything cut out. No lights, no starter and completely dead. It seemed like the brief noise was the starter activating but it was so quick I’m not sure. Had to leave for work so I haven’t had a chance to check anything yet. I’m assuming the main fuse blew. Are there known starter problems? Could the battery have shorted out? Thoughts? Of course I was planning on riding to the MotoAnerica races tomorrow...
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post #2 of 19 Old 08-23-2019, 08:51 AM
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Main fuse a good place to start; if fuse blown, the "why?" presents a challenge, especially if the malfunction is intermittent.

Go to the races anyway, with a pocket full of spare fuses!

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #3 of 19 Old 08-23-2019, 09:01 AM Thread Starter
2nd Gear
 
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Yeah, that’s the plan. Just wondering if this was a known type issue
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post #4 of 19 Old 08-23-2019, 09:56 AM
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I'll suggest loose cable terminals or internal battery failure due to the noise. Did the noise sound like a sizzle? Fuse would be a silent failure.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 19 Old 08-23-2019, 12:37 PM Thread Starter
2nd Gear
 
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It was so brief I can’t be sure but I thought it was the starter motor engaging then silence and no power at all. I’ll be done in an hour and will be sure to update what I find. You guys have been so helpful I try to give what little info I have back.
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post #6 of 19 Old 08-23-2019, 03:52 PM
Neutral
 
Join Date: Aug 2018
Location: Raleigh, NC
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Test the battery again. Without a load the battery might seem fine....put a load on it and you may discover that it's actually dead.
Put on multi-meter, check voltage, turn on bike and try the starter: see if the voltage tanks

Above withdrawn....saw your follow up post. That sux!
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post #7 of 19 Old 08-23-2019, 04:31 PM Thread Starter
2nd Gear
 
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Ok what I thought was a solenoid clicking now actually sounds to me like a loud buzz like a short coming from the starter area when I hit the starter switch. Narrowing it down. With they key off the battery is showing 12.6 volts. With the key on it drops to about 9 volts. With the key on but the main wiring harness disconnected above the main fuse voltage remains at around 12.6 volts. The other minor fuses don’t seem to have any effect on battery voltage whether plugged in or not.

Last edited by EricZ; 08-23-2019 at 05:06 PM.
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post #8 of 19 Old 08-23-2019, 06:05 PM Thread Starter
2nd Gear
 
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Please See pic. Disconnected starter via the outer Phillips screw the main wire to the starter and the battery voltage still drops from 12.6 to 9 volts when the key is turned on so it doesn’t seem to be the starter. Disconnected main harness via inner Phillips screw main wire that seems to power the main wiring harness and battery voltage stays at 12.6 with key on. Would seem to be something in the main harness but it’s not blowing any fuses. I did find a melted connector for the fan temperature switch at the bottom of the radiator on the left side and the connector wires burned off. It looked like it shorted out and melted. I was thinking it was cooling circuit related since the fan sensor harness was melted but it’s not the fan motor or temp sensor because I disconnected them and the voltage still dropped. Any Ideas please. Hoping to ride to racetrack tomorrow for Superbike races
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Last edited by EricZ; 08-23-2019 at 07:31 PM.
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post #9 of 19 Old 08-23-2019, 08:53 PM
Pretty in Pink, dunno why
 
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You have a dead battery. Replace it.

It may show over 12 volts but it will not support a load. The buzzing sound you hear is the solenoid contacts vibrating. They will operate because they present very little load. As soon as they make contact the battery sees the load of the starter motor and sharts its choners. Then the solenoid contacts go again, the battery sharts again, and over and over making a buzzing sound.

BTW, the battery voltage should be more like 12.6V.

You can still push-start the bike.

Tom [email protected]

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“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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Last edited by Tom Schmitz; 08-23-2019 at 08:56 PM.
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post #10 of 19 Old 08-23-2019, 09:02 PM
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I'd like to see a picture of the melted fan switch connector and melted wires. That is very unusual. Check the fan fuse. It should be 15A and should have blown.

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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