KLR600B2 1986 Starting / Kickstart Problems

SS427 · Oct 16, 2024

Hi all, 86 B2 model has sat for a few years unused. Prior to this the previous owner had some engine work carried out, inc new Wosner piston, chains etc ( I don’t have an invoice that itemises exactly what was done )
I tried kicking it over but there was no resistance on the kickstart lever.
I then connected up a battery, pressed the starter button and all I got was a whirring sound which then stopped and now nothing happens when the button is pressed.
Tried the kickstarter and it worked as it should, with the engine having plenty of compression.
I went through the gears and they all engage, I also rocked it back and forward in 5th gear, the engine turned over and the engine seems to have plenty of compression.
Any ideas ?
starter motor is new from when the engine was over hauled a few years ago.

Tom Schmitz · Oct 16, 2024

Do not try to get the engine running again by using the Kickstarter. That way lies madness and chiropracticity.

Quite obviously, something in the e-start train is not working correctly. The motor spins some reduction gears that engage the ring gear on the sprag clutch, and the sprag clutch has its ramps and balls in a recess on the back side of the rotor. You'll need to remove the stator/cover to see all the bits and workings. You need to see the starter motor turn over, engage the gears, and spin them around. If you see all of that, then I would suspect the sprag clutch at the back of the rotor has gotten stuck from sitting for so long.

Fixing that will require removing the rotor so that you can see what's amiss with the sprag clutch.

The kickstarter not engaging on the first attempts, meh. I will write off that as more stuckage due to disuse that solved itself.

The above are not diagnoses or solutions; they are merely clues.

SS427 · Oct 17, 2024

Tom Schmitz said:
Do not try to get the engine running again by using the Kickstarter. That way lies madness and chiropracticity.

Quite obviously, something in the e-start train is not working correctly. The motor spins some reduction gears that engage the ring gear on the sprag clutch, and the sprag clutch has its ramps and balls in a recess on the back side of the rotor. You'll need to remove the stator/cover to see all the bits and workings. You need to see the starter motor turn over, engage the gears, and spin them around. If you see all of that, then I would suspect the sprag clutch at the back of the rotor has gotten stuck from sitting for so long.

Fixing that will require removing the rotor so that you can see what's amiss with the sprag clutch.

The kickstarter not engaging on the first attempts, meh. I will write off that as more stuckage due to disuse that solved itself.

The above are not diagnoses or solutions; they are merely clues.

Hello Tim, thanks for reply. Much appreciated.

KLR600B2 1986 Starting / Kickstart Problems

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