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'08 KLR650 Starting Issues - clug, clug, clug, CLUNK

975 Views 40 Replies 13 Participants Last post by  pdwestman
I am having some issues with my 2008 KLR, pretty much stock mechanically.

Late last year I was riding my bike to work when it stalled when coming to a stop. It would not start up again and sounded like a battery issue - indeed I was able to get it to start with a battery jumper. It drove for about another 1/2 mile before stalling again at the next stop sign. This time it would no longer start even when encouraged by the jumper. The video linked at the bottom does a decent job showing the behavior when attempting to start. One thing to note that is a little hard to pick up on in the video is that when the "clunk" happens it appears to kill all electrical for a brief moment.

I have attempted to scour the web, including this forum, for something that sounded the same but came up empty handed. The bike sat all winter and the only changes have been purchasing a new battery. The closest results that I have found seem to hint towards a possible compression issue. I have not carried out any compression testing...I have never done one before and it intimidates me to be honest. Other than that, it seems like it could be a whole host of things that I found in other threads...but as I mentioned they don't seem to exactly match my symptoms.

I am pretty much a noob when it comes to this stuff and am throwing myself at the mercy of some of you experts out there.

Let me know if I am missing any background information that would be helpful in diagnosing.

Thanks in advance.

The site doesn't like my link for embedding the video, not sure why. Here is the link: YouTube Link
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That is really frustrating but you are in good hands in this forum. I know from personal experience with my bike being down for a summer and trying to troubleshoot it. There are lots of experts here that know the KLR inside and out. In general people suggest starting making sure the fuel, spark, air, and compression are working properly to systematically diagnose the problem. I’ve linked a post with the way I tried to move though the diagnosis process, including my first compression check. Your bike sounds different than mine did so hopefully a more simple fix. KLR650 turns over but doesn’t start
Is that a new battery in your youtube vid?
Start with the battery
Voltage should be closer to 13 than 12 and should not drop below 10 when cranking, I saw 7.
Drain the fuel the carb has a small screw on the bottom of the bowl. Get some fresh gas.
My bike had made that noise with a low battery.
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You want to start with the simple things first. I am wondering if the vacuum diaphragm in the petcock
could have failed and the engine simply ran out of fuel.
The battery voltage is definitely on the low side. Do you have a proper charger for a motorcycle battery?
First get the battery next pull the carb off to give it a thorough cleaning as in the thread”care and feeding of the CVK40”. Someone will post the link to that, I am unable to. Then deal with the clunk if it still exists. Good luck.
listened to the video - that battery may not be fully charged but in my opinion is spinning the starter and motor well enough the bike should start. (if it had fuel). you rode the bike then it quit. so fuel should be ok too. in the video it cranked a good number of times then a single pop - meaning you seem to be firing the spark plug. bike that run generally dont just quit running. a really bad battery could cause poor firing of the plug, but your battery is cranking the starter ok. Hmmmmm m
“The bike sat all winter and the only changes “have been purchasing a new battery.
What about this??
That's the typical sound of a low batt. I'd give it a good charge, check the connections and try again before looking anywhere else.
Start with the battery
Voltage should be closer to 13 than 12 and should not drop below 10 when cranking, I saw 7.
Drain the fuel the carb has a small screw on the bottom of the bowl. Get some fresh gas.
My bike had made that noise with a low battery.
I looked into this a bit further last night. The bike had been sitting so the battery was slightly low as you mentioned. I attached my portable jumper which bumped it up to 13 VDC and took another video (see link below). The issue persisted and what struck me as odd was that it rapidly depleted my portable jumper and as you can see the battery level drops significantly while cranking and by the end of the video you can hear it start to make the typical dead battery clicks. It seems as though there is an abnormally large power draw while cranking. I also tried disconnecting my fuse block that powers all of my aftermarket devices such as my voltage meter/charger shown in the video and fog lights just in case there was an issue with them causing additional power draw. No luck.

Starting issue video #2
What about this??
The issue happened before I stored it away for the winter.
I would start by charging and testing the battery. I have seen new batteries that were no good.
I would start by charging and testing the battery. I have seen new batteries that were no good.
I put it on the charger last night. I will check it again when I get home. I am not sure how to test a battery other than making sure it holds a charge. Any recommendations on what you would do to test the battery?
What are you using for a charger? Did you buy the battery at a local shop? If so they may test it for you.
What are you using for a charger? Did you buy the battery at a local shop? If so they may test it for you.
It is a Schumacher charger/maintainer that I set the mode for atv/motocycle size battery. I purchased the battery online so no luck there. Although now that you mention it, I realize I do have a battery shop near my work. I am sure they could test it for me.
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I had a battery shipped to me once and it had some rough treatment along the way.
It only lasted a short time, you could see bent plates inside through the white plastic case.
How long since you changed/ cleaned the plug?
I nursed a weak battery once and it turned my plug black.
Have the battery checked, fresh gas, fresh plug, let us know what happens.
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How long since you changed/ cleaned the plug?
I nursed a weak battery once and it turned my plug black.
Have the battery checked, fresh gas, fresh plug, let us know what happens.
Good advice. I will check the plug and drain the fuel/refuel as others have suggested.
I would start by charging and testing the battery. I have seen new batteries that were no good.
I put it on the charger last night. I will check it again when I get home. I am not sure how to test a battery other than making sure it holds a charge. Any recommendations on what you would do to test the battery?
What are you using for a charger? Did you buy the battery at a local shop? If so they may test it for you.
It is a Schumacher charger/maintainer that I set the mode for atv/motocycle size battery.
I've seen way too many new batteries that were initially charged with automatic charger/maintainers THAT never got FULLY charged the first time, because those 'chargers' go into maintenance mode at TOO Low of voltage before saturating the plates with electrons.
Therefore those batteries are Never able to become Full Strength and Never last very long!

Have you EVER let your engine oil run get below the oil level window. The engine does sound a little 'tight' to my long distance ears.

But hopefully a new spark plug, fresh gas and a Strong battery will light its fire.
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I've seen way too many new batteries that were initially charged with automatic charger/maintainers THAT never got FULLY charged the first time, because those 'chargers' go into maintenance mode at TOO Low of voltage before saturating the plates with electrons.
Therefore those batteries are Never able to become Full Strength and Never last very long!

Have you EVER let your engine oil run get below the oil level window. The engine does sound a little 'tight' to my long distance ears.

But hopefully a new spark plug, fresh gas and a Strong battery will light its fire.
The battery appears to take and hold a full charge at 13.2 VDC, but I have not yet had it professionally tested.

The oil hit a low point once shortly after I bought it. I checked it after an extended highway commute, and it was below the sight glass. I have kept an eye on it since and it appears to slowly lose oil, but not at an alarming rate.

I drained the fuel last night and was going to do the spark plug until I realized it requires a thin wall socket. Ran over to ProCycle today and picked one up along with a new plug. Hopefully I can manage the time to knock that out tonight. Do you recommend any additives for the fuel to help clean up the carb. since it was sitting for the last several months?
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