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post #1 of 10 Old 09-27-2012, 01:58 PM Thread Starter
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Join Date: Sep 2012
Location: death valley, CT
Posts: 9
new in CT

I take delivery of a 05 KLR on Saturday.

Looking fwd to the dual sport community.

I spend a good amount of time at ZRXOA forum (same screen name), and hit several rallies a year...prolly have 7k on my rex this year...

i'd post pics stuff, but apparently I haven't paid the cover charge.

help a brother out and kickstart the conversation...

or, i'm gonna have to start post whoring your threads...

or, start an oil, filter, vendor, etc thread...

JB
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post #2 of 10 Old 09-27-2012, 03:27 PM
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Yeah, as a guard against spammers, you need 15 posts before you can put up photos.. It sucks, but it eliminated a huge amount of spammer activity.

I need to see if there's a button that could be pushed once you've proven yourself not a spammer.. And your first post pretty much did that..
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post #3 of 10 Old 09-27-2012, 03:28 PM
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Oh, and welcome!!!

I see in your interests you like shooting.. Guns are evil.. If you get a chance, check out my shooting subforum.. http://www.klrforum.com/group.php?groupid=3
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post #4 of 10 Old 09-27-2012, 04:26 PM
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Welcome to the forum, hydrashoks. Enjoy your new KLR!



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post #5 of 10 Old 09-28-2012, 03:04 PM Thread Starter
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hey thanks fellas,

I have to do my research on the Doohickey mod, anyone wanna tell me the shortcut on how to tell if it's been done before?

theres 16k on the one I'm picking up tomorrow...

JB
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post #6 of 10 Old 09-28-2012, 03:06 PM Thread Starter
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Quote:
Originally Posted by Paper View Post
Oh, and welcome!!!

I see in your interests you like shooting.. Guns are evil.. If you get a chance, check out my shooting subforum..
ooooooo....I love the Guns & Bowses forum on the ZRXOA, great back room, with some really knowledgeable members...

toooo bad i cannot post pics of some of my recent black gun builds...
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post #7 of 10 Old 09-30-2012, 05:31 PM
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Quote:
Originally Posted by hydrashoks View Post
ooooooo....I love the Guns & Bowses forum on the ZRXOA, great back room, with some really knowledgeable members...

toooo bad i cannot post pics of some of my recent black gun builds...
10 more posts..
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post #8 of 10 Old 10-07-2012, 10:37 AM Thread Starter
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Join Date: Sep 2012
Location: death valley, CT
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OK. well I'll prolly start another thread for better visibility, but lemme get some feedback here from you fellas that might be watching this one...

SO, i cannot figger why it wont start any way other then in neutral. I havent taken the controls apart, but where it the damn clutch bypass, how does it work, etc....it should from what here is telling me, start in any gear w the cluch pulled in...it doesnt. I also noticed that when i tightened the bark buster, that when the clutch was pulled in, it didnt return all the way out. stupid design. HELP w this if you have spec knowledge, i'm still searching for a factory service manual.

NEXT BIGGER PROBLEM.

I LOST THE DAMN EXHAUST FROM THE HEAD PIPE BACK ON THE HIGHWAY FRIDAY!!! How the F does this happen?
I don't even have a full tank of gas thru this...cornering into an on-ramp, it dissapeared...drove it 10mi home w just the head pipe...looked under there, no clamp on the head pipe and apparently there's 2 mount holes on the rider's RHS frame, where it should have been fastened.
So pissed.
Called the dealer, and the sales manager said that he'd reach out to the boss...no reply. Called them the next day, and he said that he still hadnt heard from the boss, and that the boss would call me Tuesday...

Fvcking BS.

Anyone have any advice on a slip on pipe that doesnt need re jetting? if not, a pipe / jet kit combo?
Who the F doesnt check this on a bike before they sell it?

Last edited by hydrashoks; 10-08-2012 at 09:12 AM.
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post #9 of 10 Old 10-08-2012, 02:03 AM
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Join Date: Sep 2012
Location: East Coast of Australia
Posts: 21
Hi hydrashosks,
Welcome!!!
I too own a 05 & I know the NOT-START-IN-GEAR-FAULT.

Under the clutch lever pivot point there are 3 wires running into a small thin switch. The holes for these screws are slightly elongated and this allows the centre part to move just enough for the contacts on the clutch safety switch to not contact, thus no starting in gear.
You can loosen the screws off a bit and slide the center bit backwards and forwards to see if you can get the thing to start in gear while pulling in the clutch.
BE CAREFUL THEY SOMETIMES LURCH FORWARD EVEN WITH THE CLUTCH PULLED IN.
If this solves it... Yay...all good. Time for beer.

FOR THE FOLLOWING BE AWARE THAT THE BIKE MAY LURCH FORWARD SO BREIFLY TAP THE STARTER TO CONFIRM THE CIRCUIT IS WORKING ONLY... AND BE READY!!!
ALSO DON'T FORGET THE BIKE WONT START IF THE SIDESTAND IS DOWN WHILE IT IS IN GEAR, SO RIG IT UP SO YOU CAN DO THE FOLOWING WITHOUT THE SIDESTAND BEING DOWN OR ANY LURCHING.

Carefully dismantle the switch and you'll see just how basic a design it is...just make sure you don't drop the contact bush out of the lever.
There are three contact points one long & two short.
If you short across one of the short ones (I forget which) to the long one this should close the circuit and allow the starter to kick while the bike is in gear.
Scrub these contacts with some fine grit paper and reassemble and test.
Don't forget that the center bit may need to be wiggled exactly right for the bits to contact.
That's what I did and it's been fine ever since.

Failing all of this you can permanently short the switch by shorting across the appropriate wires or contacts so it will start in gear but this is disabling a safety so would be considered a dangerous option and YOU DO IT AT YOUR OWN RISK!!!! In fact you follow any advice from me at your own risk.
Good luck. Make sure you post back how you went.

P.S. Bummer about the exhaust. Got no advice for that bit...

Last edited by sticksnstones; 10-08-2012 at 02:07 AM.
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post #10 of 10 Old 10-08-2012, 09:09 AM Thread Starter
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outstanding reply Sir, thanks for the info!!!
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