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Discussion Starter #1 (Edited)
Hey KLRers out there. My 600b2 model is acting funky.

Been using the kick start since I got it last year, but decided to replace the missing starter pieces.

I installed a starter that is verified working (via direct line from battery), a new battery, verified starter relay ( cross terminals and she kicks, so I know the big wires are good) and got a replacement relay that acts exactly the same..

So here goes: bike in neutral, clutch in or out, key on, switch in run position, press the magic button and <click> i hear the relay click, plain as day. But nothing else happens! So it gets it's signal from the switch at the handlebars in order to click. Thus, starter switch is working. What else can I test/check?

So what do i do now?

Thanks for any input!
Friedom:chopper:
 

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Discussion Starter #4
I got a used solenoid to replace, and it acts exactly the same. But I'll try the radio on the sol anyways. Is there another starter safety switch somewhere else on the klrs aside from the kickstand and clutch?
 

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I had the same issue with the starter on my KLR600... Went over everything with a DMM and verified that all the electrics are good... Starter is fine when attached direct to the battery....

Turned out that the KACR had been cut from the camshaft causing higher compression on start which the starter just didn't have the power for.
 

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If the STARTER relay (beyond the starter CIRCUIT relay) clicks, no safety switch defeats the starting sequence.

If the great big cable is securely connected between the battery positive terminal and the starter relay, and the short heavy cable is securely connected between the starter relay and the starter motor, but nothing happens beyond the click: I'd suspect defective/high-resistance contacts in the starter relay.

I understand jumping the starter motor directly with + 12VDC turns the engine over; supplying positive current to the starter is the usual task of the starter relay. If the starter relay doesn't provide current to the starter motor when the relay is activated, I'd suspect the starter relay is falling down on the job.

'Round about Figure 39 of Chapter 9 (page 201) in this link, you'll see a good diagram of the starting circuit:

http://www.diagramasde.com/diagramas/otros2/Kawasaki+KLR+650+(1987-2003+clymer).pdf

Unleash a multimeter, and you should find your problem.
 

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Discussion Starter #7
I just saw your message after I stared for a long time at the wiring diagram. Sure enough, the Starter Circuit Relay is what was clicking. The Starter Relay itself is doing nothing. I have a replacement Starter Relay that I can swap out with it, but now that I have an idea of how these things are supposed to work, and that there are indeed TWO relays, I can probably get this guy going.

Thanks thanks thanks!

If the STARTER relay (beyond the starter CIRCUIT relay) clicks, no safety switch defeats the starting sequence.

If the great big cable is securely connected between the battery positive terminal and the starter relay, and the short heavy cable is securely connected between the starter relay and the starter motor, but nothing happens beyond the click: I'd suspect defective/high-resistance contacts in the starter relay.

I understand jumping the starter motor directly with + 12VDC turns the engine over; supplying positive current to the starter is the usual task of the starter relay. If the starter relay doesn't provide current to the starter motor when the relay is activated, I'd suspect the starter relay is falling down on the job.

'Round about Figure 39 of Chapter 9 (page 201) in this link, you'll see a good diagram of the starting circuit:

http://www.diagramasde.com/diagramas/otros2/Kawasaki+KLR+650+(1987-2003+clymer).pdf

Unleash a multimeter, and you should find your problem.
 

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I just saw your message after I stared for a long time at the wiring diagram. Sure enough, the Starter Circuit Relay is what was clicking. The Starter Relay itself is doing nothing. I have a replacement Starter Relay that I can swap out with it, but now that I have an idea of how these things are supposed to work, and that there are indeed TWO relays, I can probably get this guy going.

Thanks thanks thanks!
You're certainly welcome, Friedom!

BTW; just FYI, the starter circuit relay is identical to the fan relay on your bike (assuming KLR600/KLR650 commonality); thus, you always have a ride-along spare!

Before you give up entirely on your starter relay, JUMP the heavy-gauge cable connection to the smaller connection (the one that goes to the starter circuit relay); if the starter motor turns over when the starter relay is so jumped, your starter circuit relay may be defective.

A sort of parallel or alternate test; when the starter circuit relay CLICKS, see if + 12 VDC comes forth from the connection to the starter relay . . . it SHOULD, if operating normally.
 

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Discussion Starter #9 (Edited)
it's the starter CIRCUIT relay... looks like a pretty common part, wonder if I can find one locally.

Thanks again!

If the STARTER relay (beyond the starter CIRCUIT relay) clicks, no safety switch defeats the starting sequence.

If the great big cable is securely connected between the battery positive terminal and the starter relay, and the short heavy cable is securely connected between the starter relay and the starter motor, but nothing happens beyond the click: I'd suspect defective/high-resistance contacts in the starter relay.

I understand jumping the starter motor directly with + 12VDC turns the engine over; supplying positive current to the starter is the usual task of the starter relay. If the starter relay doesn't provide current to the starter motor when the relay is activated, I'd suspect the starter relay is falling down on the job.

'Round about Figure 39 of Chapter 9 (page 201) in this link, you'll see a good diagram of the starting circuit:

http://www.diagramasde.com/diagramas/otros2/Kawasaki+KLR+650+(1987-2003+clymer).pdf

Unleash a multimeter, and you should find your problem.
 

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it's the starter safety switch... looks like a pretty common part, wonder if I can find one locally.

Thanks again!
Well, maybe so, Friedom, but--seems like the starter circuit relay wouldn't even click, if the clutch safety switch was misbehaving.

Your bike, but--you might consider BYPASSING a balky safety switch; plenty of how-to instructions and even video clips exist on the Web.

Good luck at getting your electric starter sorted out; I envy you your KICKSTARTER! :)
 

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Discussion Starter #11
Absolutely right, damoclese. I mis typed in all my excitement.
...post updated...

I bypassed the kick stand safety switch. Debating the clutch bypass still.

Say, what kind of sword do you brandish? :)
 

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Say, what kind of sword do you brandish?
One whose blade is made of Damascus steel, Friedom; forged from a meteorite, folded and hammered many times, resulting in an incredible number of layers. My sword is both terrible and swift.

:)

Forgot to mention; that sword hangs above my head, suspended only by a HAIR!
 

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One whose blade is made of Damascus steel, Friedom; forged from a meteorite, folded and hammered many times, resulting in an incredible number of layers. My sword is both terrible and swift.
And sharp enough to cleave the occasional Gordian Knot. ;^)

T
 
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