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post #1 of 7 Old 10-14-2008, 01:25 PM Thread Starter
Join Date: Oct 2008
Posts: 18

I Was Goin To Work Last Thursday Morning And Notice My Head Light Was Going Dim, I Went On To Work About A Nother 15 Miles Shut The Bike Off, Came In And Got My Volt Meter And Checked My Battery Voltage It Was About 13v. That Told Me That The Stator Was Still Charging. I Then Turned The Key On And Had No Lights, Starter, Horn Nothing Worked At All. Could It Be In The Key Switch??? I Then Pushed The Bike In To The Shop After Work That Evening Turned The Key On And All Was Ok. I Road The Bike Home All Still Was Ok, I Took Off All The Plastic Seat Etc. And Checked All Wiring And Fuses All Was Ok. This Has Me Stumped, Any Suggestions??? Battery Is Only About 5 Months Old And Connections Were Tight To The Battery.:
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post #2 of 7 Old 10-14-2008, 01:42 PM
3rd Gear
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Join Date: Nov 2007
Location: Corpus Christi, TX
Posts: 704
First thing I'd do is go back over all the wiring and check for rubs and breaks. Might as well clean up all the connectors you can get to while you'r doing it. Pretty common according to posts here.
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post #3 of 7 Old 10-14-2008, 02:06 PM
4th Gear
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
Check the main male/female connector by the fuses. I had an issue where my bike ran fine to a friends house and then when I went to leave it wouldn't do anything. No lights horn nothing. Tried to push start..Nothing worked. Finally took the seat off and just for the hell of it..pulled that connection apart and looked at it. It looked to be connected at the time. Reconnected it and all was fine. We have run into maybe two other bikes locally that would have the same issue. Put some di-electric grease in that and I used a zip tie to make sure the connection of that fitting stayed tight all the time.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #4 of 7 Old 10-14-2008, 04:48 PM
2nd Gear
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Join Date: Jun 2008
Location: Central AZ
Posts: 177
Good advice given, I like your handle

Don H
Spring Valley AZ
'03 KLR 650/DS sidecar
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post #5 of 7 Old 10-14-2008, 07:25 PM Thread Starter
Join Date: Oct 2008
Posts: 18
Thanks for the help
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post #6 of 7 Old 11-13-2008, 11:24 AM
1st Gear
Join Date: Nov 2008
Location: Cape Town, South Africa (Southern tip of the African continent)
Posts: 63
Thumbs up Bike slugging along with no power, I have the solution.

Yankee, And whoever else has this problem I have owned my KLR from new and had the exact same problem, which started a little after a 15 day 4.500km trip . 1st I stripped the fuel tap and removed the self stopping/tap fuel device, do diference. 2nd I stripped the carb, blew everything clear, rebuilt the carb...samo problemo. 3nd Checked the CDI, nothing wrong there. 4th Took the muffler off and rode down the road just on the U tube........WHAT A NOISE, but she went like a supercharged Thunderbird on steroids...So...just take a steel rod (12mm / 1/2inch) and hammer it down into the muffler till it stops against something hard...This of course takes some balls as which twit would want to rape a new bikes me it works...something to do with the baffles collapsing onto each other when the bike is ridden at constant revs for extended periods.
The exact same thing plaged my son on a return trip from up-country, bike would not getr more than 50km and was sucking gas big time. After lots of searching he found a length of steel rod and drove it down into the muffler..hey presto, bike back to normal power and not noticabley louder.

Good luck

Humpty Dumpty
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post #7 of 7 Old 11-17-2008, 12:26 PM
1st Gear
Join Date: Nov 2008
Location: Cape Town, South Africa (Southern tip of the African continent)
Posts: 63
Oops, think I posted to the wrong request for help and now cant find the one I thought I was helping, sorry chaps, see what comes from wearing too tight a helmet. He, He!
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