Cold start issue - Kawasaki KLR 650 Forum
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post #1 of 10 Old 03-13-2020, 10:08 AM Thread Starter
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Cold start issue

Hi all, I bought a 2001 KLR 650 last year. Runs great! Love the bike. Problem is, when the temp drops to 15 degrees celcius less, it doesnt want to start. If I put a heater on it, it starts no problem. It turns over just fine, but wont fire. Plugs are good, new battery. Any tips?
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post #2 of 10 Old 03-13-2020, 03:02 PM
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Quote:
Originally Posted by Warrenlee View Post
Hi all, I bought a 2001 KLR 650 last year. Runs great! Love the bike. Problem is, when the temp drops to 15 degrees celcius less, it doesnt want to start. If I put a heater on it, it starts no problem. It turns over just fine, but wont fire. Plugs are good, new battery. Any tips?
Too many new owners can Not Resist playing with the throttle on motorcycles. It is NOT a '57 Chevy pickup with a manual Choke & an accelerator pump in the carb, nor a '67 Chevy with an automatic Choke & an accelerator pump.

It Does Not Even have a "Choke" plate and has no accelerator pump either.
Rather it has a separate Cold Start Enrichener System. By opening the throttle it allows Too Much extra air in with-out passing over the Enrichener Jet first. Effectively making it too Lean to achieve a cold start.

Check cold start lever cable slack, about 1/8th inch?

First I need you to keep your hand Completely off of the RH hand grip!

Pull Enrichener lever full ON. Key On. Kill switch on. Use your RH INDEX Finger to push and HOLD the starter button for 3-4 seconds of continuous cranking.
None of this tap, tap, tap crap. Crank it!

If it did not start on the 4th exhaust pipe pulse, Stop Cranking. Count to ten. Let the raw fuel we sucked in vaporize a bit.

Using your Index Finger again, Crank IT. If your valve tappets are Not near or worse yet Below minimum specs & your carburetor jets, including the non-removeable Starter Jet is as clean as you think they are, it should now be running.

If it does not start with these procedures we can discuss it some more.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 10 Old 03-13-2020, 06:29 PM Thread Starter
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Thanks for the explanation. Much appreciated. However, I do not give it gas or apply the throttle when cranking it over.
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post #4 of 10 Old 03-14-2020, 10:44 AM
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It might surprize you how little of throttle input can defeat reliable cold starting! Therefore the index finger suggestion.
Did you try my Crank & Pause method? Did it not work on your bike?

Then maybe it is past due for a Cold Cranking Compression test with the throttle Wide Open. We need 77-124psi. 85psi & up is preferred.
Time to purchase a Clymer Service Manual, unless you already own one.

If CCC is more than 77psi, you probably need to adjust enrichener cable and/or clean the carburetor.

If CCC is less than 77psi, it is probably past due time to measure, record and re-adjust the valve tappet clearances. We need to keep clearances in the upper half of specs for best CCC, for best cold starting.

Intake tappets, .004 - .008 inches / Exhaust tappets, .006 - .010 inches.
Valve shims are only available in .002" increments & we really don't want sloppy fitting maximum clearances (causes un-necessary valve tick) . Just lightly snug on thickest gauge or chose different shim size.

Then re-check CCC to see how much we gained & is it now enough or does your bike have more serious issues?
Weav likes this.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 10 Old 03-14-2020, 04:17 PM Thread Starter
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Oh boy! Haha this is beyond my capabilities. Thankfully I have a good friend who is a mechanic. He just hasn’t worked on the KLR’s before. I’ll give this stuff a try!! Thanks
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post #6 of 10 Old 03-14-2020, 04:57 PM
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"It might surprize you how little of throttle input can defeat reliable cold starting! Therefore the index finger suggestion.
Did you try my Crank & Pause method? Did it not work on your bike?"

These 2 questions still need answers.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #7 of 10 Old 03-14-2020, 05:35 PM Thread Starter
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Yes I did try it. No go
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post #8 of 10 Old 03-15-2020, 04:26 PM
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I will suggest to your mechanic to check CCC first. If below 80 psi and valves have not be checked in the past 10,000 miles to your knowledge then they should be checked & adjusted to upper half of specs. Recheck CCC.

If the CCC is above 80 psi, remove carb first & concentrate on cleaning the non-removeable starter jet, pilot jet, 3 tiny transition holes under bottom lip of throttle plate & the adjustable idle mixture screw.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #9 of 10 Old 03-15-2020, 06:47 PM Thread Starter
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Man you know your stuff!! Thanks.
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post #10 of 10 Old 04-05-2020, 02:32 PM Thread Starter
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Hey so I’ve tried a couple of times now. Still not starting. I guess I’m into the v
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