help 2001 klr 650

Discussion in 'Thumpers' started by stimmer6253472, Jul 18, 2013.

  1. stimmer6253472

    stimmer6253472 Been here awhile

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    Dec 1, 2008
    Oddometer:
    366
    Location:
    Belton, Mo.
    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.
    #1
  2. ruppster

    ruppster Long timer

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    If you have a voltmeter handy, things to check: Kill switch, side stand switch, and start relay.
    #2
  3. East Coast Rider

    East Coast Rider Just Me...

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    Don't forget the clutch safety switch. Battery connections tight?
    #3
  4. millahtime

    millahtime Adventurer

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    SoCal, but close enuff to walk to the beach
    #4
  5. stimmer6253472

    stimmer6253472 Been here awhile

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    it is an intermittent problem sometimes it works sometimes it doesn't. battery is okay because the lights work.
    #5
  6. RandoCommando

    RandoCommando Wannabe

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    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.
    #6
  7. Grinnin

    Grinnin Forever N00b

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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. :puke1

    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.
    #7
  8. ruppster

    ruppster Long timer

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    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".
    #8
  9. augiedog

    augiedog augie dog

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    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.
    #9
  10. KustomizingKid

    KustomizingKid Been here awhile

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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.
    #10
  11. Kawidad

    Kawidad Long timer

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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.
    #11
  12. travelinggnome

    travelinggnome TravelingGnome

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    Atlanta, GA
    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.
    #12
  13. XDragRacer

    XDragRacer Long timer

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    #13