questions, questions, questions?

[T&M]

Can't remember who mentioned it earlier about a toasted starter, but there is one for sale on ebay for 20 bones starting bid. Timan http://cgi.ebay.com/ebaymotors/aw-cgi/ebayISAPI.dll?ViewItem&item=569912752& r=0&t=0

[gtx]

Hi guys, has anyone had problems with the starter not engaging? I just replaced the one way clutch and I still have the hassle of a starter that seems to more often than not just whine instead of engaging the engine, going to perform open heart surgery at WE unless someone knows what could be the problem. Regards Gary 85 KLR600 [Non-text portions of this message have been removed]

[southampton12000]

Do the starters go bad? I have an 05 in Mx. Battery is good, connections at terminal good. Bike has been sitting for 6 months. Push started and click, nothing more. Advice? thanks, brian

[Jeff Saline]

On Tue, 15 Nov 2011 23:32:45 -0000 "southampton12000" writes:

> Do the starters go bad? > I have an 05 in Mx. Battery is good, connections at terminal good. > Bike has been sitting for 6 months. Push started and click, nothing > more. > Advice? > thanks, brian

<><><><><><><> <><><><><><><> brian, Sounds like a dead/dying battery to me. Not too often that you hear of a KLR650 starter going bad. Not too sure what Mx means. How did you determine the battery is good? If fully charged the battery should ready 12.6 volts. Turn the key on so the headlight is working and after a few minutes the voltage should probably be about 12.4 volts. When you push the starter button what does the voltage reading do? Right now with the info provided I'd say you have a bad/dead battery. 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 . . ____________________________________________________________ 53 Year Old Mom Looks 33 The Stunning Results of Her Wrinkle Trick Has Botox Doctors Worried http://thirdpartyoffers.juno.com/TGL3141/4ec30a795bf91b5505st06vuc

[Jeff Saline]

On Wed, 16 Nov 2011 02:24:57 +0000 (GMT) barrettb@... writes: Thanks for the reply Jeff Mx. means Mexico. I keep a bike here in the Yucatan and it has been sitting for 6 months. I just put a new battery in today. I thought the same. Then when it didn t start, I jumped it with a car battery. Same thing , no go. Same click. I am thinking the starter or maybe rusted connections at the starter/ground. What say yee? thanks, brian <><><><><><><> <><><><><><><> brian, I just want to make sure you have the kill switch on the right handlebar switch in the run position. : ) I'm guessing the click you are hearing is the starter solenoid on the left side of the bike above the footpeg, behind the black plastic cover. It has two heavy battery cables going to it and also two small wires in one connector. Might be worth putting an ear near it and making sure that's the clicking sound you are hearing. I suppose it could also be a clicking sound from arcing at a bad connection. If that is correct that it's the solenoid clicking... when you push the starter button it sends electricity to the solenoid and the solenoid should electrically connect the two heavy wires. When that happens the starter gets energized and should spin. The heavy wire on the right side (rear of bike side) on the solenoid is the positive battery cable. The heavy wire on the left side (front end of bike side) is the wire going to the positive post on the starter and is only energized when the starter button is depressed. If either of those wires are loose at the solenoid that could keep the starter from turning. If you decide to check them make sure you don't touch the nuts and the frame with a wrench at the same time. That would be like touching the wrench across both battery terminals which is a direct short i.e. BAD. I'm also assuming the battery is put in correctly and not hooked up backwards. We've heard of that being done on here a few times. : ) When you have the ignition switch in the run position and press the starter button does the headlight dim or go out? That would be another indicator of a bad battery. If you are feeling confident and want to mess with it some more... you could try bypassing the solenoid. It will take a heavy pliers or short piece of battery cable size wire with the ends stripped and the wire bent into a "U" shape. Make sure the bike is in neutral. Roll it with the clutch out just to make sure. When you bypass the solenoid the starter should turn and hopefully the engine will start. If it's in gear the bike will jump forward. Don't blame me if you try this and jump the bike into the pool. : ) First do this with the key in the off position. The engine won't start if it cranks. Then touch the wire or one jaw of the pliers to the left nut on the solenoid. Put it on the nut and not the threads so you don't damage them. Then while continuing to touch the left nut touch the other end of the wire or other jaw of the pliers to the right nut. (Sorry, this is starting to sound dirty.) When you touch the right nut sparks might fly but the engine should crank. That is how to bypass the starter solenoid. You can then do the same thing with the key in the run position and the fuel on. You should be able to start the bike. If this works the starter solenoid is probably bad. Of course it could be a bad connection of the control circuit for the solenoid. Let the list know what happens. 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 . . ____________________________________________________________ 53 Year Old Mom Looks 33 The Stunning Results of Her Wrinkle Trick Has Botox Doctors Worried http://thirdpartyoffers.juno.com/TGL3141/4ec32bdbc8c15c18dbst05vuc [Non-text portions of this message have been removed]

[Jeff Saline]

On Wed, 16 Nov 2011 13:21:10 +0000 (GMT) barrettb@... writes: Jeff, I jumped the solenoid with a pair of needle nose plyers (sp). Starter engaged. Now, my wife is coming to Mx. on Sunday. There is no way to get parts here so if she brings a solenoid down is it hard to put in. Should I try to take the soleniod out and clean it up? Thanks, brian <><><><><><><> <><><><><><><> brian, Now you know the starter motor and heavy current circuit work. That means the problem is with the control circuit which includes the starter button, clutch switch, neutral switch, starter circuit relay, all the wiring connecting them and the starter solenoid low current relay. Let's eliminate or confirm it's really the starter solenoid that is bad. On the solenoid in the front middle you should see a white plastic connector. It should have two wire going to it. One wire is black and yellow, that is the ground wire. The other wire is black and is the positive wire. Make sure the connector is pushed on tightly. Get a short piece of electrical wire maybe 4"-5" long. Lamp cord size wire is fine. Strip about 1/2" of insulation from each end and if it's multi-strand wire twist the end so you don't have strands sticking out. Bend it in a "U" shape. Again, make sure the bike is in neutral. Put one end of the "U" shaped test wire in the connector with the black wire. Touch the other end of the "U" shaped wire to the terminal on the solenoid with the heavy wire coming from the battery positive terminal. The starter should crank. If it does crank it tells you the starter solenoid is working correctly and you have a problem in the earlier mentioned parts. If it doesn't crank take another short piece of wire (maybe 18" long) and strip insulation from the ends. Put one end in the connector with the yellow/black wire and connect the other end to ground. Ground can either be on the battery negative terminal or on the frame with some bare metal. With this wire in place try the first test again with the short wire in the black wire connector and touching the heavy wire from the battery positive terminal. If the bike cranks now try it again but this time instead of using the short wire turn the key on and push the starter button. If it then works it's a ground wire problem between the solenoid black/yellow wire and ground. If it still doesn't crank it's the solenoid. Before I would replace the solenoid I would unplug the white plastic connector and try the tests again going right to the terminals in the solenoid. If it still didn't crank I'd smack it on the side with a heavy tool and see if it then worked. Sometimes they get stuck, especially if someone tried to crank the engine with a bad or discharged battery. Low voltage means high amperage and that means lots of current and sparking. If the solenoid tests good what I'll guess is bad is either the starter circuit relay or the clutch switch adjustment or a connection in the wiring. Did you ever figure out exactly what is clicking? The starter relay is next to or below the starter solenoid. I don't remember exactly as I've changed my component locations when I added a second radiator to my KLR. But it's a cylinder shaped component about the size of a roll of quarters. The wires (four if I recall correctly) plug into the end. Those are known to go bad and are the same as the fan relay. So you have another one on the bike you can use for testing purposes. Test the solenoid first and if that is not the problem let the list know and we'll move forward with testing the starter circuit relay. 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 . . ____________________________________________________________ 53 Year Old Mom Looks 33 The Stunning Results of Her Wrinkle Trick Has Botox Doctors Worried http://thirdpartyoffers.juno.com/TGL3141/4ec3d23959201ecb9est04vuc [Non-text portions of this message have been removed]

[Jeff Saline]

On Wed, 16 Nov 2011 10:39:02 -0500 Blake El Explorador writes: Taking out the solenoid and replacing it is a piece of cake. As soon as you've disconnected the wires leading to it you just have to wiggle and pull the rubber holder it rests in and it will pop right off. -Blake <><><><><><> <><><><><><> Do make sure to disconnect the battery ground cable before messing with the cables on the solenoid. 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 . . ____________________________________________________________ Hyatt Summerfield Suites® All Suites Hotel with a Full Kitchen. Free Breakfast & Wi-Fi. Book Now http://thirdpartyoffers.juno.com/TGL3141/4ec3dca1d704f0be6st05vuc [Non-text portions of this message have been removed]

[Jeff Saline]

On Wed, 16 Nov 2011 16:56:00 +0000 (GMT) barrettb@... writes: Progress has been made! short wire connecting the black part of plastic connector to pos terminal and nothing. long wire connecting black/yellow to neg battery pole works with ignition switch and bike kicked right over after sitting 6 months. ok, so problem is solenoid black /yellow wire and ground? Do you think it is the plastic connector? thanks, brian <><><><><><><> <><><><><><><> brian, Well Done!!! Take a look at the tail light and see if it works. It uses the same ground as the solenoid control circuit. The coil also uses the same ground so if the bike runs... My guess is the tail light works and the engine runs and that would suggest that it is the connector or a broken wire near the connector. You'll probably have to remove a little tape and trace the wire. Look and feel for a break. You could also hold the starter button in while moving the wire and when the bike cranks you know that's the location of the break or bad connection. The problem is the bike might not crank while you wiggle wires and connectors. : ( I'd probably unplug and replug the connector a few times and also look at the connections and make sure they look well seated in the connector and are tight. 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 . . ____________________________________________________________ Get Free Email with Video Mail & Video Chat! http://www.juno.com/freeemail?refcd=JUTAGOUT1FREM0210 [Non-text portions of this message have been removed]

[Jeff Saline]

On Wed, 16 Nov 2011 17:18:53 +0000 (GMT) barrettb@... writes: So, I pulled out the long wire connecting blak/yellow to ground and no start. Then I started to push together any connectors I could see. I pushed the black/yellow wire in towards the plastic connector, now the bike starts! Without any jumpers, the way it is supposed to. My only question now is, what did I do? I really don't know what, how or where the ground connection was bad. What do you think, could it be a bit of corrosion in the plastic connector? Thanks for the time and help. You got it going! Brian <><><><><> <><><><><> Brian, Probably just a loose connection in the plastic connector. They get that way either from the factory not being seated fully or from vibration or poking around them. : ) I think you fully seated the wire to the connector. I'd quit messing with it if it was mine and enjoy the ride. Oh, don't forget to check the oil every time you put fuel in it. 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 . . ____________________________________________________________ 53 Year Old Mom Looks 33 The Stunning Results of Her Wrinkle Trick Has Botox Doctors Worried http://thirdpartyoffers.juno.com/TGL3141/4ec3f27d31d21f96dest05vuc [Non-text portions of this message have been removed]

[dat brooklyn bum]

Dollar to a donut, it's just that the female plug(s) inside the white plastic connector have ovalled a bit from vibration. Pinch them together to get a better connection and you're probably all set. I've had this happen on 2 of 4 KLRs I've owned... da Vermonster

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote: > > On Wed, 16 Nov 2011 16:56:00 +0000 (GMT) barrettb@... writes: > Progress has been made! > short wire connecting the black part of plastic connector to pos terminal > and nothing. > long wire connecting black/yellow to neg battery pole works with ignition > switch and bike kicked right over after sitting 6 months. > ok, so problem is solenoid black /yellow wire and ground? Do you think > it is the plastic connector? > thanks, brian > <><><><><><><> > <><><><><><><> > > brian, > > Well Done!!! > > Take a look at the tail light and see if it works. It uses the same > ground as the solenoid control circuit. The coil also uses the same > ground so if the bike runs... > > My guess is the tail light works and the engine runs and that would > suggest that it is the connector or a broken wire near the connector. > > You'll probably have to remove a little tape and trace the wire. Look > and feel for a break. > > You could also hold the starter button in while moving the wire and when > the bike cranks you know that's the location of the break or bad > connection. The problem is the bike might not crank while you wiggle > wires and connectors. : ( > > I'd probably unplug and replug the connector a few times and also look at > the connections and make sure they look well seated in the connector and > are tight. > > 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 > > . > . > > ____________________________________________________________ > Get Free Email with Video Mail & Video Chat! > http://www.juno.com/freeemail?refcd=JUTAGOUT1FREM0210 > > > [Non-text portions of this message have been removed] >