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what is going on here

Posted: Tue Oct 07, 2014 11:54 pm
by denvowell
I was putting my bike away for the winter.I added sea foam to the gas tank. Started  it to let sea foam get to the carb.The bike quickly went to hot and started dumping anti freeze from high on the engine.shut it off. Then it would not start/ Replaced fuse under seat.It blew.Tryed agin Samething along with fan fuse. Took off tank to check for short.nothing I could find;Took out and tested thermistate . Seems ok.Put it all back togather.Every thing seams fine,Starts ;runs ;no leaks;fan works,What happened?   Dennis In a message dated 10/6/2014 1:46:54 A.M. Eastern Daylight Time, DSN_KLR650@yahoogroups.com writes:
[color=#000000]  Funny stuff Rev....sorry to hear about ribs. Come to Texas for ribs (Bar-B-Que). Criswell putting my bike away Sent from my iPad On Oct 5, 2014, at 3:43 PM, "Martin Earl mjearl4@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com> wrote:  

Background-- I am not a suspension expert, but I do have some opinions based on experience...and I am always willing to learn something new! I have 2 KLR's in the stable (father/son) equipped as: (1998/685) One KLR has progressive F/R springs appropriate for my weight (ask Fred for advice)  plus Gold Valves  (the front springs/vales were there when I bought it.) (2001/650) One KLR has Progressive F, no valves. OEM shock. cough (replaced 3x) First:  We also need to confess, the KLR650 is not a 'full-time' trail bike for the average joe. smile. now, don't we all feel better? Your question first needs to address, where/how does Robert ride? The most useful article I ever read, addresses the primary question of:  q.  Are you hitting the bottom of your forks and rear springs multiple times each ride? a.1   Yes.  You are not stiff enough. a.2   No.  You are to stiff. 1.  In my experience (IME) Progressive Springs (PS) are NOT a cure all; but they can cure specific riding 'problems'.    I have them in my high-speed "prairie bike" where we ride fairly clean =very small ruts, stutter stretches of  gravel/dirt at higher speeds. This suspension is also very appropriate for the long distance KLR multi-surface riding.  Usually, I love the way this bike is set up, cough- However, The PS sucks on a trail where full deflection is best/needed 90% of the time; crossing multiple washes, small boulder fields, ruts, repeat.  I installed the PS front/rear because I was hitting the bottom of the forks and rear spring multiple times... and made it a joy to ride,  but when I moved TO the Black Hills, where there are more-different surfaces, the present suspension  made the bike nearly useless = less pleasant for riding off road in the Black Hills.  That is why they make the KLX. shrug. Short term cures: Switching back and forth on the front springs is not difficult...I still have the OEM front springs, but switching the rear spring is problematic. grin. I also know you can fine tune the oil weight, as well as the volume...and I wish I knew more or had a tutorial on the fine arts of that 'tuning' as well. A recent discussion of the Gen 1 KLR was 190mm oil level in the front forks.  yada, yada, yada.  IME, that should be 'interpreted' as a starting point; such as 21psi F 28psi R tire pressures. = it is all an average, you know, a 160# rider that rides sanely. shrug.  Not sure I ever met one of those.... I am presently tink ering with change of oil volumes, = change of airspace making the KLR more trail worthy. I am also going to detune the 2001 to OEM springs, 5w oil as the offroad, off pavement KLR to compliment the KLX250. I also ride the intermediate trails with 14psi F/R which makes the KLR650 a much better bike, especially around rocks. AS you pursue the suspension tuning, I would also suggest that you make JUST ONE correction at a time; just one of course unless you have 'adult supervision' by someone who is a suspension exert. shrug. Anyway, 1 change the springs, use same oil weight etc. 2 change oil weight 3 add cartridges etc 4 change oil weight It is amazing what just changing the fork oil will do. = new, or weight change. Another unsolicited data points. If your bike has more than 30K on the forks, the inner bushings are likely shot or nearly so = good time to replace them. Fred has them in stock.  Will be on your bench on Wednesday (if not sooner). IME, the only fork seals I would (EVER) buy/replacement are OEM.    Fred has them as well...never met another dealer that had them in stock, no not one. and one last point: the best upgrade to the KLR650 I have ever made was the KLX250, and it opened up a whole new world of 'enjoyable' riding. Lighter, better suspension, appropriate/adequate amount of power and I can pick it up (usually) by myself. What I also noticed-- With the 650, I broke ribs; with the 250, I only separated ribs. blush. uh, in more, remote places. YMMV.  revmaaatin. On Sun, Oct 5, 2014 at 9:53 AM, RobertWichert http://mailt o:robert@..." >robert@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: So I have a fork seal leak on the right fork.  I think it is out of oil.  Based on all that came out and it stopped. Is it worthwhile, in your esteemed opinion, to switch to different springs, emulators, imitators, anything at all worth doing when I am changing the seals, which are probably shot at 31,000 miles.  Is that too soon? Thanks for thinking about this... -- Robert Wichert P.Eng. 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what is going on here

Posted: Wed Oct 08, 2014 12:31 pm
by Norm Keller
I'd be looking for the short to ground as it will likely bite you later when time is not so good. Is it Gen1 or 2?
 
First thing, I'd check to see if the fan shroud is bent, if there is something which can get into the fan shroud area to jam the fan from turning. This might blow the Main Fuse but should blow the Fan Fuse which should be of smaller value. Check to see what amp is the fan fuse compared with the Main. If the Fan Fuse is smaller than the Main Fuse, the problem should be in the wiring "before" the Fan Fuse since a smaller fuse can't pass enough current to blow a bigger fuse. Some wiring diagrams suggest that not all Gen1 have a fan fuse but I can't recall seeing a KLR650 which lacked one.
 
If it blew the main fuse, the short to ground might be better localized with some more information. Did the fuse blow with the key off and grounding the thermal fan switch? If so, the ground is "before" the ignition switch. As said above, if it has a Fan Fuse of proper value, the problem has to be before the Fan Fuse. If only when the fan is run, consult the wiring information I linked and see that the White wire comes from the battery to power the electrical system. The White wire goes from battery to Main Fuse to White Wire which splits to the Fan Relay or Ignition Switch or VRR.
 
I recommend that you place a large sized resistance such as a headlight bulb or even turn signal bulb in place of the fuse. This bulb will illuminate when there is a good circuit to ground provided by the White Wire.
 
Disconnect the VRR Plug, Ignition Switch Plug (Plug C or 23 in my diagrams) which is the center one under the black plastic bucket below the instrument cluster. It's the only six wire plug. And disconnect the fan motor plug so that the motor is not in the circuit.
 
Play around with the fan switch to see if grounding it will cause the bulb in place of the fuse to light. You can confirm that the bulb is correctly in the circuit by using a jumper wire to ground a White wire such as the one in the VRR plug. Grounding will turn on the bulb. Again, I doubt the Fan circuit after the Fan Fuse because of the values.
 
You will likely find that there is an intermittent short to ground somewhere and this will be indicated by that bulb coming on as it should not do so with the plugs disconnected. It will likely be in the area around the front of the tank so push, rub, press to try to get the light to come on.
 
Hope this is useful. If you prefer, send me a direct email and will try to help.
 
This reminds me that I still have not opened up the wiring harness to show connection points so will try to get started today.
 
 
 
 

Tue Oct 7, 2014 9:54 pm (PDT) . Posted by:

denvowell@...?subject=Re%3A%20what%20is%20going%20on%20here

I was putting my bike away for the winter.I added sea foam to the gas tank. Started it to let sea foam get to the carb.The bike quickly went to hot and started dumping anti freeze from high on the engine.shut it off. Then it would not start/ Replaced fuse under seat.It blew.Tryed agin Samething along with fan fuse. Took off tank to check for short.nothing I could find;Took out and tested thermistate . Seems ok.Put it all back togather.Every thing seams fine,Starts ;runs ;no leaks;fan works,What happened? Dennis

wiring identification -additional

Posted: Wed Oct 08, 2014 3:05 pm
by Norm Keller
#ygrps-yiv-433016828 blockquote.ygrps-yiv-433016828cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-433016828 blockquote.ygrps-yiv-433016828cite2 {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;margin-top:3px;padding-top:0px;} #ygrps-yiv-433016828 .ygrps-yiv-433016828plain pre, #ygrps-yiv-433016828 .ygrps-yiv-433016828plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;} #ygrps-yiv-433016828 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-433016828 .ygrps-yiv-433016828plain pre, #ygrps-yiv-433016828 .ygrps-yiv-433016828plain tt {font-family:Tahoma;font-size:12pt;} Here are links to some of the harness wiring junction points/connections inside the harness loom wrapping.   They are near the battery end and around the junction where the harness branch from the battery connections join the main harness run and towards the VRR and rear.   One can see that there are two common ground junction points at about equi-distant (2-3 inches) from the point where the battery wiring branch joins.   https://www.dropbox.com/s/kw44fmc4hvxshzc/Harness%20Junction%20Points1.jpg?dl=0   https://www.dropbox.com/s/3kr7fpbftfxii1v/Harness%20Junction%20Points2.jpg?dl=0   https://www.dropbox.com/s/kwdkwlmno37kuq2/Harness%20Junction%20Points3.jpg?dl=0