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Old 07-18-2013, 12:19 PM   #1
stimmer6253472 OP
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help 2001 klr 650

I'm in Colorado on vacation and my KLR 650 won't start like it's completely dead. battery is okay but when I push the start switch nothing happens. please help.
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Old 07-18-2013, 12:21 PM   #2
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If you have a voltmeter handy, things to check: Kill switch, side stand switch, and start relay.
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Old 07-18-2013, 12:40 PM   #3
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Don't forget the clutch safety switch. Battery connections tight?
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Old 07-18-2013, 12:45 PM   #4
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I'm with the other guys.

battery connections, side stand and clutch safety switch.

check here for the latter two.

http://www.klr650.marknet.us/Safety_Bypass.pdf
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Old 07-18-2013, 12:58 PM   #5
stimmer6253472 OP
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it is an intermittent problem sometimes it works sometimes it doesn't. battery is okay because the lights work.
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Old 07-18-2013, 04:23 PM   #6
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Quote:
Originally Posted by stimmer6253472 View Post
it is an intermittent problem sometimes it works sometimes it doesn't. battery is okay because the lights work.
I'm gonna bet it's the side stand switch sticking.
Remove the plastic cover and move the switch manually when it won't start.
You'll need to have the kick stand in the up position when you do this.
Might need to replace the cable or lube it up really well.
Or disconnect the circuit or remove the cable.
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Old 07-18-2013, 05:17 PM   #7
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If it's the sidestand switch then it should still start when in neutral.

The neutral switch and clutch switch can prevent it from starting. If you have a neutral light then the neutral switch is working OK and it should start in neutral.

That leaves just about the rest of the electrical system.

I had a similar problem last week in Minnesota. For me it turned out to be the last inch of ground wire with an intermittent break. To find it I had to go over the electrical system bit by bit. For checking ground I took apart plugs, found the black-with-yellow wire, and looked for 0 ohms from there to the negative terminal. The fault being intermittent made it harder to find.
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Old 07-18-2013, 06:21 PM   #8
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Quote:
Originally Posted by stimmer6253472 View Post
it is an intermittent problem sometimes it works sometimes it doesn't. battery is okay because the lights work.
I had that problem with my 93. Check the start relay connections and give it a tap with a wrench, mine acted like it was starting to get "sticky".
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Old 07-18-2013, 07:43 PM   #9
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start problem

It is likley the start switch itself . turn the key on , be sure its in nutural, push the start button and wiggle it around alittle while pushing in on it. it should start. KLR's are prone to getting corrosion on the switch connector points. If this corrects the start problem you need to remove the housing and spray the switch contacts with something like wd-40.
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Old 07-18-2013, 07:55 PM   #10
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Check the starter relay... If the rubber holder falls off (mine disintegrated) and the starter relay touches the metal bracket wrong it won't start. I have to lift mine up, anti theft device hahaha.
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Old 07-19-2013, 09:13 AM   #11
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I had a similar problem with my 2000. I thought it was the starter relay and bought a new one. (I already got rid of the side stand and clutch switches.) Didn't solve the problem, then a mechanic buddy told me it was likely the starter motor itself. Over time they develop flat spots where the brushes don't make proper electrical contact. Tapping the starter motor briskly with a hammer got it going every time. However, the fix for me was a new starter motor.
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Old 07-19-2013, 09:49 AM   #12
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I had the same problem one afternoon and it was as simple as one of the leads (in my case it was the positive lead) to the starter motor having worked its way loose. I would start there as I spent hours fiddling with other things when all that was necessary was connecting one wire back to the motor.
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Old 07-19-2013, 11:37 AM   #13
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The clutch safety switch can lock out the starter; wiggling the clutch lever sometimes encourges it to straighten up and fly right.

Otherwise, a multimeter and this wiring diagram might be useful:

http://www.wiringdiagrams21.com/wp-c...ng-diagram.gif
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