gas tank vent hose

[jeffniss]

for me it was the brushes being stuck in the up position in there holders the starter motor. I just opened the motor up, freed the brushes, cleaned things up a bit with a flathead srewdriver. put it back and worked like new (I just got a click at the relay with nothing before)

[Pat Schmid]

This weekend, and three occasions when pressing the starter button nothing happened. Once I bump started the other two times, after turning the ignition key on and off several times and moving the engine stop switch the starter finally respondde to pushing the button. Symptons: 1) No precuser to Sunday's woes. The problem came out of the blue 2) On sunday the bike was dropped in a big dust bog, but problem did not sart until about seven restarts later. 3) Don't suspect the ignition switch as all other electrics were working My own suspesion is something on the starter button/kill switch circuit. Because the problem came and went it sounds more like a bad connector/switch. Main question would be as anyone had a starter solenoid that acted like this on its way out? Pat G'ville, Nv

[Jim]

Pat, Check the connections at the starter solonoid under the black plastic guard on the left side below the tank. I had this same problem and found a loose hot connection and have not had a problem since. --Jim A-15

> This weekend, and three occasions when pressing the starter button > nothing happened. Once I bump started the other two times, after > turning the ignition key on and off several times and moving the > engine stop switch the starter finally respondde to pushing the button. > > Symptons: > 1) No precuser to Sunday's woes. The problem came out of the blue > 2) On sunday the bike was dropped in a big dust bog, but problem did > not sart until about seven restarts later. > 3) Don't suspect the ignition switch as all other electrics were working > > My own suspesion is something on the starter button/kill switch > circuit. Because the problem came and went it sounds more like a bad > connector/switch. Main question would be as anyone had a starter > solenoid that acted like this on its way out? > > Pat > G'ville, Nv

[RS]

I had the same problem and it drove me crazy, I fixed it by accident, it was the stupid clutch/kickstand kill switch located in the clutch lever perch, when I bent my crappy OEM lever and perch and replaced it with a good one, I twisted the correct 2 wires together,( look at the switch and move it back and forth to see which 2 ),and put a wire nut on them, and taped off the other one, I have never had that problem again, and now I can lube my chain like I always had before the KLR by putting my bike in first gear and leaning it on its kickstand and let the chain spin, and if you have to have a switch to tell you to engage the clutch before you start it in gear, you will learn fast without it. Pat Schmid wrote:This weekend, and three occasions when pressing the starter button nothing happened. Once I bump started the other two times, after turning the ignition key on and off several times and moving the engine stop switch the starter finally respondde to pushing the button. Symptons: 1) No precuser to Sunday's woes. The problem came out of the blue 2) On sunday the bike was dropped in a big dust bog, but problem did not sart until about seven restarts later. 3) Don't suspect the ignition switch as all other electrics were working My own suspesion is something on the starter button/kill switch circuit. Because the problem came and went it sounds more like a bad connector/switch. Main question would be as anyone had a starter solenoid that acted like this on its way out? Pat G'ville, Nv List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Unsubscribe by sending a blank message to: DSN_klr650-unsubscribe@yahoogroups.com . Yahoo! Groups Links --------------------------------- Do you Yahoo!? Friends. Fun. Try the all-new Yahoo! Messenger [Non-text portions of this message have been removed]

[Conall]

I've also had this same problem (and fix) that Jim refers to... Conall

--- In DSN_klr650@yahoogroups.com, "Jim" wrote: > Pat, > Check the connections at the starter solonoid under the black plastic > guard on the left side below the tank. I had this same problem and > found a loose hot connection and have not had a problem since. > --Jim > A-15 > > > This weekend, and three occasions when pressing the starter button > > nothing happened. Once I bump started the other two times, after > > turning the ignition key on and off several times and moving the > > engine stop switch the starter finally respondde to pushing the button.

[kdxkawboy@aol.com]

In a message dated 2004-05-25 5:33:39 AM Pacific Daylight Time, A14@... writes:

> > One possible solution. Try spraying a generous amount of contact cleaner, > WD40, or similar into the starter button and kill switch. I had this > problem after getting 'dusted' by MVH last year. Your 'big dust bog' seems > to be the cause. > > Walt > A14 "War Horse" > > >

The dust bog I fell in was the consistency of Pillsbury's finest. In going down the starter switch housing got rotated on the handle bar so it took something of a hit - under the dust there was a rut I couldn't see and the rear tire dropped in the rut while the front stayed out and then the rear started spinning against the side of the rut and BAM!. When I pulled apart the starter switch I found an oddity. On the spring there was a cobweb caked in dust. I think that fall provided the dust and then vibration caused it to fall between the button and the contact and vibration caused it to fall it and then back in and then back out. The cobweb was secured to the spring and with the caked on dust it was flapping about. Pat G'ville, Nv [Non-text portions of this message have been removed]

[Mike Torst]

Corrosion, loose contacts,? Mike Torst Las Vegas

> -----Original Message----- > From: Conall [mailto:klr650dotcc@...] > Sent: Tuesday, May 25, 2004 1:32 PM > To: DSN_klr650@yahoogroups.com > Subject: [DSN_klr650] Re: Starter Problems > > I've also had this same problem (and fix) that Jim refers to... > > Conall > > --- In DSN_klr650@yahoogroups.com, "Jim" wrote: > > Pat, > > Check the connections at the starter solonoid under the black > plastic > > guard on the left side below the tank. I had this same problem and > > found a loose hot connection and have not had a problem since. > > --Jim > > A-15 > > > > > This weekend, and three occasions when pressing the starter button > > > nothing happened. Once I bump started the other two times, after > > > turning the ignition key on and off several times and moving the > > > engine stop switch the starter finally respondde to pushing the > button. > >

[Conall]

I had a loose connection at the starter solenoid that inhibited the bike from starting. Being a little bit of a slacker, I left it as-is , and use the no- start feature as a theft deterrent now. Conall --- In DSN_klr650@yahoogroups.com, "Mike Torst" wrote:

> Corrosion, loose contacts,? > > Mike Torst > Las Vegas > > > -----Original Message----- > > From: Conall [mailto:klr650dotcc@h...] > > Sent: Tuesday, May 25, 2004 1:32 PM > > To: DSN_klr650@yahoogroups.com > > Subject: [DSN_klr650] Re: Starter Problems > > > > I've also had this same problem (and fix) that Jim refers to... > > > > Conall > > > > --- In DSN_klr650@yahoogroups.com, "Jim" wrote: > > > Pat, > > > Check the connections at the starter solonoid under the black > > plastic > > > guard on the left side below the tank. I had this same problem

and

> > > found a loose hot connection and have not had a problem since. > > > --Jim > > > A-15 > > > > > > > This weekend, and three occasions when pressing the starter

button

> > > > nothing happened. Once I bump started the other two times,

after

> > > > turning the ignition key on and off several times and moving

the

> > > > engine stop switch the starter finally respondde to pushing

the

> > button. > > > >

[Geoff]

I have an 87' with 28K on the ticker and I have noticed a clicking sound after I did the valves that goes up and down with the RPM's, but I let it go because it ran fine for months. On a quick trip, about 16 miles, the sound went away and it was nothing but the thumping of the piston and the exhaust, it was great, something I had not heard it quite awhile. After I did what I set out to do, I headed for home, but about 4 miles into the trip, the bike started sounding funny, throughing off expensive sounds, then some lurching, like the timing was being screwed with, so I shut the key off and coasted to the shoulder. I thought the "doohickey" gave up the ghost and was about to spread it self around the bottom of my engine like tack's on a basket ball court and I think I shut her down before that happened. So, I got the complete kit from Fred and with the help of Mark's step by step web site I got the "doo" changed with out enough metal in the bottom to worry about. After she was back together, I had a hard time starting her(I must say, she sat for almost two months from the time she left me hitching a ride). I did get it turned over, but it sounded funny. After a few tries she came to life, but thats when I noticed a foul noise, it was the starter, it was still engaged! Even as I reved the engine, it was trying to turn at the same speed! This caused the bike to run like crap, of course! But also the starter sounded like it was about to fly to the moon. So, to make a long story longer, has anyone ever had a starter NOT dis-engauge or any other less than normal wear cause problems? Do I need to replace the starter, or can I rebuild it? Any input would be MORE than welcome, I really want to ride again! GM

[Jeff Saline]

On Thu, 19 Oct 2006 09:56:25 -0000 "Geoff" writes:

> I have an 87' with 28K on the ticker and I have noticed a clicking > sound after I did the valves that goes up and down with the RPM's, > but > I let it go because it ran fine for months.

SNIP I got the "doo" changed with out enough metal in the

> bottom > to worry about. After she was back together, I had a hard time > starting her(I must say, she sat for almost two months from the > time > she left me hitching a ride). I did get it turned over, but it > sounded > funny. After a few tries she came to life, but thats when I noticed > a > foul noise, it was the starter, it was still engaged! Even as I > reved > the engine, it was trying to turn at the same speed! This caused > the > bike to run like crap, of course! But also the starter sounded like > it > was about to fly to the moon. So, to make a long story longer, has > anyone ever had a starter NOT dis-engauge or any other less than > normal wear cause problems? > Do I need to replace the starter, or can I rebuild it? > Any input would be MORE than welcome, I really want to ride again! > > GM

<><><><><><> <><><><><><> GM, On the KLR the starter is always engaged with two little gears which inturn are engaged with the large gear that is has what most folks call a sprag unit (like a one way clutch). The sprags allow the gear to rotate freely in one direction and lock up in the other. So when the starter shaft is rotating faster than the crankshaft (through the gears) it is locked up. When the crankshaft is rotating faster than the starter it rotates. That's basically how it's supposed to work. Sounds like your sprags are fully locked. I think I'd take a look at the work I just did and confirm the issue. I kind of recall in the back of my mind someone on the list had a similar problem when doing the doo as they cleaned and dried the sprags and then installed the gear. Having it dripping oil is ok and probably makes reassembly easier. In a starter drive using a solenoid to kick the starter drive gear and one way clutch in and out of engagement with the ring gear it would be a starter issue when the gear stays engaged. Good luck with this. I'll be interested in hearing what you learn. The metal in the bottom is of particular concern. It had to come from somewhere. Did you open the top of the engine and take a look at the cams and valve components? Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT