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Discussion Starter #1
I recently purchased a 1986 KLR 600 project bike. Initially was told that the only issue was a bad CDI unit. Not so fast. Fast foward to 2 months at a shop getting a spark the bike still will not run. now have spark but has a wicked kickback while trying to start. Actually destroyed the key on the flywheel.
Mechanic got tired of messing with it but suggested the timing could be off by about 10 deg.Thinking the flywheel isnt correct I ordered a used one on E Bay only to find out the serial numbers are identical.I am used to working the old 2 stroke engines such as the ts 185 so this one is a slight learning curve.
 

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Discussion Starter #3
Klr 600

I replaced the flywheel and still have the same issue. Backfiring but did run for about 15 seconds. I just got back from dropping the bike off to a new mechanic.
Fingers crossed.
 

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I have faith that once you get this going, and you are traveling down the back roads and trails you are going to have a huge smile across your face. You have a great bike which is pretty rare here in the states as they were only sold for 3 years. Hopefully the new mechanic will be skilled enough to fix it properly, and then once you are at that point it will be a matter of just keeping up with the maintenance.
 

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Klr 600

I totally agree.
The 600 will definately be nimble on gravel as well as trails.
I do ride backroads on a Tiger 955 but its a tad heavy. The 600 will be a more versatile machine to go a little further.
 

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Welcome to the forum. Do you have a manual for the bike. If you keep having a shop work on it , you will soon have a very expensive machine. With a book you can ask questions on this forum and get informed answers. Have you checked the valve timing and the spark timing. Ride safe (soon) James
 

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Discussion Starter #7
Klr 600

Hello James.
I do agree with you regarding the cost. My main goal initially was to just get the engine turning over. Once the basics were sorted out it would be a project for me to take over. The previous mechanic did go through the timing and made some adjustments.
Initially the issue was no spark.Bad ignition coil, bad pickup and bad grounds were the issue there.This bike has been sitting in a barn since 2000.
At this point its a little over my head so I wouldnt be comfortable tearing into it at this stage.
A little bit of expert help will hopefully set me on the correct path and I definately will be leaning on the experts here in the future when the major bugs have been sorted out.
All the best!
Niall
 

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let's see this thing!

if you google "KLR600 manual" it's one of the first few links that pops up. i have a nice gross stained printed out copy in my garage.

like they said before, check your valves and carb. my choke has been a big time culprit for me, so if you get an idle and you die with throttle when your choke is up, try to start it again without choke. not sure of why it loves to make everything so difficult, but shit happens.

get this bike on the road dawg!!!!
 

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Discussion Starter #11
I finally got the bike running. The issue was the CDI box that i purchased was firing at the wrong time which in turn caused a backfire.
Purchased a new box and it fired up in an instant.
i have taken it out on short runs on gravel so far. very happy with this bike. Roll on summer time.
 
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