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Discussion Starter #1
Replaced battery test drove everything OK. Started up this morning and starter kept cranking wore out battery,Wires looked fine fuses OK. What do I check next?
 

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Hi. What year is the bike?

Why was the battery replaced?
Were there any starter malfunctions going on before the battery was replaced?
Are you SURE that the negative terminal at the battery is NOT grounding on the frame?

FYI: If it happens again, the kill switch will disable the starter.

Do you have a means of recharging the battery?
 

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It is an 04 that had the original battery. The old battery wasn't turning over the starter which is why I replaced it. Charging the battery again but missing a 300 mile ride today. All connnections seemed to be fine but I must have either misgrounded it or will have to check wiring by starter. Thanks
 

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My guess is one of two components is messing up on you.



Starter Relay. The positive cable from the battery runs to this. It is under the black cover on the left side of the bike. The mid section has a rubber boot oaround it, below you can see the bottom, kind of a brass looking part. Tap this brass end. This unit is spring actuated, and, the spring can hang up.



Starter / kill switch assembly. look for signs of arcing and corrosion.



Starter button. Pretty high tech. Check for signs of arcing, corrosion. WD40 works for me as a cleaning fluid to loosen and flush away crud.
 

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Late question, but did the bike actually start this morning during the stuck starter episode? Or did it just crank until you had no battery left? I'm trying to see if the starter circuit relay may be involved. Unlikely, but....
 

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Yes it did start but the starter kept cranking. Going to try and tap the bottom. Local dealer said that the problem could have been caused by the same thing. Many Thanks. Can you give advice on a website showing how to change sprockets and chain and should I replace the doo hicky. Bought the bike used last year with 6000 miles now have over 18000.
 

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Get yourself a Clymer manual. Changing a sprocket and chain is not too hard. As to the Doohickey, yes you should definitely replace it. Do you know what shape it's in?
 

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Yes it did start but the starter kept cranking. Going to try and tap the bottom. Local dealer said that the problem could have been caused by the same thing. Many Thanks. Can you give advice on a website showing how to change sprockets and chain and should I replace the doo hicky. Bought the bike used last year with 6000 miles now have over 18000.
I'm drawing a blank on a good site for chain and sprocket replacement. While it is a relatively simple process, on a scale of difficulty from 1 to 10, a chain and sprocket kit would rate a "5". If proper chain tensioning were not such a critical issue, it would rank a "3". I suggest you start another thread, and a step by step procedure could be put together. You might want to discuss sprocket tooth count and chain options, and current vendor bargains. KLR riders know where the deals are.
 
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