--- In DSN_klr650@y..., "Gord Mounce" wrote: > This sounds like it might also be a charging problem, as a new battery cured it for about a week. You might want to spend a minute checking that out before digging into the starter. > > good luck with it > gord >
chain and sprocket removal
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- Posts: 366
- Joined: Tue Dec 04, 2001 11:54 pm
starter problem
That was my first thought, took the new battery back to the sho where
I bought and they assured me it had been properly charged and
everything looked fine with it. They put it on the charger again just
to be sure and with a fresh charge, still no go.
dat brooklyn bum (pray for a bad relay!)
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- Posts: 366
- Joined: Tue Dec 04, 2001 11:54 pm
starter problem
Damn,
I go to check out the bike last night at midnight-30 and it started
right up. Can you test for an intermittently faulty relay? BTW there
is no plastic cover over my relays....never was (bought the bike
used). I'm going to try to clean all the contacts and grease 'em up
with some fancy stuff. What's best to clean electrical contacts? WD40?
The problem seems to surface in wet conditions if that helps the
diagnosis doctors.
dat brooklyn bum
--- In DSN_klr650@y..., Jim Hyman wrote: > Tumu, > > There are two relays in the starter system: > 1) Starter Circuit Relay (with 4 regular wires) > 2) Starter Relay (with 2 heavy wires and a plastic connector with 2 > regular wires) > > Remove the plastic cover (below the petcock) that protects both > starter relays. Feel both relays with one hand while you press the > starter button. If the "main" relay clicks but the motor doesn't > spin, this relay is probably NFG. Before you tear into the starter > motor, use the handle ends of a set of pliers to connect the two > heavy wires on the starter relay. If the motor spins, you have a > faulty starter relay. DON'T let the pliers touch any part of the > engine or frame!! > > Be sure to check the heavy ground (earth) wire where it connects to > the base of the starter motor (under the carb) for tightness and > corrosion. This is NOT the heavy wire that goes from the starter > relay to the starter motor. > > There are only 3 fuses in the stock wiring system: > 1) 20 amp main fuse* - for the whole system > 2) 10 amp headlight fuse* - for the headlight circuit, "euro > . circuit", meter illumination lights, & rear illumination lights > > 3) 10 amp cooling fan fuse (behind the coolant recovery tank) > > *under the seat > > Professor A9 Federal Way, WA. [USA] > > ps: Are we now even on the TP thingy? > > ++++++++++ > Bummer wrote: > > I've got a bike that won't start. Started out as intermittent and I > thought it was the start switch itself. Then I realized I still had > the same battery the bike came with (96) and bought a new battery. > that worked for about a week. Now the problem is no longer > intermittent. I push the starter button and just get a single click > (from the starter relay I assume). No starter motor engaging. Does > this sound like I need a new starter motor? Horn and lights > work...Is > there a fuse for the starter circuit separate from the main fuse > under the seat? > > If I get time I'm gonna tear into the starter motor on Thursday > morning but I want to get the bike running before the weekend so I > can go play in PA with da crew. Any and all advice on what to check > is greatly appreciated. > > dat brooklyn bum
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- Posts: 2322
- Joined: Thu May 10, 2001 9:41 am
starter problem
Sometimes relays don't "click" very loud, or hard enough to feel.
A horn relay (replaces starter circuit relay) and a starter relay (AKA
"Solenoid") from any small japanese car should work on the KLR, and both
will be in stock at Pep boys and cheap as well.
Before they die relays tend to get flakey. They're sealed, but cheap enough
to just replace for the purposes of diagnosis.
Radio shack sells an aerosol can of contact cleaning solution with a nylon
bristle brush on the tip. This works pretty well. When you get the relays
pick up a tube of tune-up grease (AKA points grease).
Devon
guymanbro wrote:
> Damn, > > I go to check out the bike last night at midnight-30 and it started > right up. Can you test for an intermittently faulty relay? BTW there > is no plastic cover over my relays....never was (bought the bike > used). I'm going to try to clean all the contacts and grease 'em up > with some fancy stuff. What's best to clean electrical contacts? WD40? > > The problem seems to surface in wet conditions if that helps the > diagnosis doctors. > > dat brooklyn bum > > --- In DSN_klr650@y..., Jim Hyman wrote: > > Tumu, > > > > There are two relays in the starter system: > > 1) Starter Circuit Relay (with 4 regular wires) > > 2) Starter Relay (with 2 heavy wires and a plastic connector with 2 > > regular wires) > > > > Remove the plastic cover (below the petcock) that protects both > > starter relays. Feel both relays with one hand while you press the > > starter button. If the "main" relay clicks but the motor doesn't > > spin, this relay is probably NFG. Before you tear into the starter > > motor, use the handle ends of a set of pliers to connect the two > > heavy wires on the starter relay. If the motor spins, you have a > > faulty starter relay. DON'T let the pliers touch any part of the > > engine or frame!! > > > > Be sure to check the heavy ground (earth) wire where it connects to > > the base of the starter motor (under the carb) for tightness and > > corrosion. This is NOT the heavy wire that goes from the starter > > relay to the starter motor. > > > > There are only 3 fuses in the stock wiring system: > > 1) 20 amp main fuse* - for the whole system > > 2) 10 amp headlight fuse* - for the headlight circuit, "euro > > . circuit", meter illumination lights, & rear illumination lights > > > > 3) 10 amp cooling fan fuse (behind the coolant recovery tank) > > > > *under the seat > > > > Professor A9 Federal Way, WA. [USA] > > > > ps: Are we now even on the TP thingy? > > > > ++++++++++ > > Bummer wrote: > > > > I've got a bike that won't start. Started out as intermittent and I > > thought it was the start switch itself. Then I realized I still had > > the same battery the bike came with (96) and bought a new battery. > > that worked for about a week. Now the problem is no longer > > intermittent. I push the starter button and just get a single click > > (from the starter relay I assume). No starter motor engaging. Does > > this sound like I need a new starter motor? Horn and lights > > work...Is > > there a fuse for the starter circuit separate from the main fuse > > under the seat? > > > > If I get time I'm gonna tear into the starter motor on Thursday > > morning but I want to get the bike running before the weekend so I > > can go play in PA with da crew. Any and all advice on what to check > > is greatly appreciated. > > > > dat brooklyn bum > > Checkout Dual Sport News at > http://www.dualsportnews.com > Be part of the Adventure! > > Visit the KLR650 archives at > http://www.listquest.com/lq/search.html?ln=klr650 > > Post message: DSN_klr650@yahoogroups.com > Subscribe: DSN_klr650-subscribe@yahoogroups.com > Unsubscribe: DSN_klr650-unsubscribe@yahoogroups.com > List owner: DSN_klr650-owner@yahoogroups.com > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/
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- Posts: 498
- Joined: Fri May 05, 2000 2:51 am
starter problem
Thanks Steve,
I think that may be the very problem because I get a click but no start. Swede mentioned he had the same part fail on him.....
Uh-oh, do I sense another doohickey panic alarm about to go off???
dat brooklyn bum (gonna bypass that damn relay and see what happens)
--- On Thu 05/30, st1anderson wrote: > > Your starter issue sure sounds like the same problem I had five or > six months ago. Turned out the culprit was flaky contacts in the > starter circuit relay. > > Might check out my write up for what happened and the way I bypassed > it: > > http://groups.yahoo.com/group/DSN_klr650/message/45348 > > Since I did this, haven't had any problems at all. > ------------------------------------------------ Join Excite! - http://www.excite.com The most personalized portal on the Web!
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- Posts: 467
- Joined: Fri Oct 25, 2002 10:45 am
starter problem
Having a problem starting. With a recently charged bty, pressed the starter and
I got a noise as if it were trying to have a dump, but was suffering from "hard
extraction", sort of a grunt, (no insult to past, present , or future Infantry).
Terminals seem to be properly connected, bty is charged up, FAQs were checked.
I put a load of WD 40 on all the muffler and exhaust bolts and left it
overnight, and now await a load of wisdom from the collective.
Thanks in advance.
DC
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- Posts: 1
- Joined: Thu Aug 03, 2006 5:49 pm
starter problem
I have a 99 model klr. When I turn on the ignition the starter starts
cranking the engine. I have tapped on the starter and the start button
on the handlebar. No luck. I then took off the starter and cleaned and
tested; worked perfect. Reinstalled worked perfect for about 3
intervals and now the sameo. Anybody had this problem??????//
Thanks ......Ron
chain and sprocket removal
The easiest way to remove the front sprocket nut is to hit it with your 1/2 drive impact gun. If you don't have one check to see if your auto repair tech will take it off for you.
HIH
Norm
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