KLR 650 Problems...

Discussion in 'Thumpers' started by KGRider, Dec 11, 2012.

  1. KGRider

    KGRider n00b

    Joined:
    Dec 4, 2012
    Oddometer:
    3
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    High Desert
    So about 2 months ago I decided to trade my 69 Cj5 for a 2001 KLR 650 to pursue my passion of riding. I have followed advrider before I even started to ride full time and love the people and the site. (little bit of background)

    It's funny because yesterday I learned all about the darn "doohickey" problems... and decided to change it as soon as I had the money. But today I took it out for a couple of trails and ran into a problem. I was in first gear going through some steep short woops and heard a sound coming from the casing and stopped, it sounded like another idle coming from the engine if that makes sense and the bike itself was a little rougher. I shut it off, checked fluids, all was good there. I wasn't to far from home and decided to ride up the last hill and could coast down a powerline road to my backyard. As I started heading up the short hill of woops the bike stalled going down the backside of a woop. I tried to start but it wasn't even trying to turn, thought the battery might of died and tried to jump but the back tire was locked. I have a bad feeling I seized the engine. What do you guys think?
    #1
  2. deepcdiver

    deepcdiver Nobody Special

    Joined:
    Jan 19, 2004
    Oddometer:
    790
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    Oaktown
    I think you are right, in that you are likely screwed. How many miles on the motor? Pull the case cover and stator and check it out. Also go to KLR650.net, those guys will know. Good luck :(
    #2
  3. KGRider

    KGRider n00b

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    10,000 miles. Yeah it makes one click when your try to start and cuts out, I will go to klr650.net and try to resolve the problem
    #3
  4. John65

    John65 D Ol Man

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    Jakin, Ga
    A friend and I rode up to north GA, rode some trails up there and then back home. He got about 4 miles from his house and had a similar problem to what you describe. He didn't try to re-start the bike, just called his wife to come pick him up.
    He took the bike to Kawi dealer and doohickey had broke, chain came off sprocket and busted side case. cost him a lot of $$$ to get it fixed.
    The dealer had told him earlier that they had never seen a doohickey break, so he shouldn't worry 'bout replacing it.
    Guess they were wrong, huh
    #4
  5. Dolly Sod

    Dolly Sod Red Clay Halo

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    Richmond, Va
    How handy are you?

    Put the bike on a center stand, pull the spark plug and try to turn the back wheel with the transmission in 5th gear.

    Check your oil for bits and pieces.

    Pull the valve cover and see if the cam chain is still there and turning the cam shafts.
    #5
  6. klrnohio

    klrnohio Adventurer

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    Mar 14, 2012
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    12
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    central ohio, Delaware
    You should try posting on KLR650.net and pm eaglemike. He's the doohickey guru. Great guy.
    #6
  7. RandoCommando

    RandoCommando Wannabe

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    Oct 12, 2011
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    Philthadelphia, Pennsylvania
    Interesting first post. :huh
    #7
  8. Beezer

    Beezer Long timer

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    Anchorage, formerly Spenard (hub of the universe)
    pull the left side cover & look. the good news is there are plenty of parts out there.

    I have done over 3 dozen doos... mebby 4 dozen. at least half had some thing bad. at least 1/3 were broken
    #8
  9. Unstable Rider

    Unstable Rider Moto Fotografist

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    Post some pics when you get it opened up pleaze / some folk still listening to the dealer
    when they say "its a non-factor" (and I agree it's a real problem)

    :deal

    Which one would you want....... the skinny smaller one from Kawasucker or the all beef version from Eagle Mike?

    [​IMG]
    #9
  10. Sierra Thumper

    Sierra Thumper Been here awhile

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    Oct 3, 2012
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    641
    #10
  11. East Coast Rider

    East Coast Rider Just Me...

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    Location:
    Stuck somewhere in motorcycle Purgatory
    :poser

    That thread is hilarious!
    #11
  12. Kbowling

    Kbowling Been here awhile

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    Feb 26, 2012
    Oddometer:
    152
    Sounds like it broke,its not to hard to replace with the right tools,but it sound like a more involved now
    #12
  13. KGRider

    KGRider n00b

    Joined:
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    Oddometer:
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    High Desert
    Okay so this morning I headed out to break it down and see what was going on in there. I was going to try two things, I was going to pull the side off and check the doohickey and springs, check for broken gears, and to see if everything was in place. Next I was going to open up the valve top and look to see if the timing chain was there, adjustments bolts were in place, and there were no shavings floating around.


    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    I started by taking the plastics off and the fuel tank. Pulled the radiator fan and sprocket cover.


    [​IMG]
    [​IMG]

    The I opened up the side cover and didn't see anything obvious that was broken or misplaced. Next was to take the Rotor bolt out to release the rotor. I didn't have a barrel wrench to hold the rotor still as I tried to break the bolt loose. I was regretting not having the right tool for the job but in my luck a friend of mine said he was going to bring over a Snap On bk6000 cylinder scope with a camera and light at the end which was really helpful. We saw that the doohickey was in tack and still no sign of why the tire was locked and it wasn't turning over. Since I had the two gears between the flywheel and the starter removed, we tried to start it to make sure the starter was working correctly which it was.


    [​IMG]
    [​IMG]
    [​IMG]


    Then we had the top valve cover and the side cover off and were messing around with the rotor bolt and a ratchet and it started turning the timing chain. Wait a second! It's turning the timing chain? :cry So maybe it was the gears between the flywheel and the starter gear? So we put the side cover and valve top back on and put some oil in and tried to turn it over, sure enough it was turning. We came to the conclusion that when I stalled, it jammed the gears or slipped the starter gear out of place.... :huh

    So the bike is all put back together and is running great now. I appreciate all of your help and look forward to riding!:D
    #13
  14. Unstable Rider

    Unstable Rider Moto Fotografist

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    wow.... weird.

    Sounds like you got lucky brother, even though you had to take the bike apart to verify all that. Consider replacing the doo and upgrading to a torsion spring anyway.

    ride on!
    #14
  15. RFVC600R

    RFVC600R SAND EATER!

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    Whoa. another reason I love old red Hondas

    Sorry to get off topic but where are you in the high desert? i need some riding buddies :D
    #15
  16. Kbowling

    Kbowling Been here awhile

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    Feb 26, 2012
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    152
    Sounds like you found the problem
    #16
  17. skwatr

    skwatr Adventurer

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    Palmetto,FL
    Im fascinated by this post. I dont even have a kawi. Im never going to get anything done if i log onto this site!
    #17
  18. Dolly Sod

    Dolly Sod Red Clay Halo

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    Richmond, Va
    Glad you fixed it, and that's one I've never heard before.
    #18
  19. CA Stu

    CA Stu Steer with your face! Super Moderator

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    48,204
    Location:
    Riverside, CA
    Just a thought... did you inspect the Woodruff key and make sure it was intact and in place? No spring bits or anything else floating around in there?

    I'm thinking maybe you got something caught in one of the internal engine chains (timing / balancer).

    Either that or when you reassembled it you put a washer / gear back in the wrong place and it got cockeyed and into a bind....

    Nothing like a mystery to start the morning... :*sip*
    #19
  20. Mr.JAJA

    Mr.JAJA Been here awhile

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    Nov 29, 2010
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    Location:
    San Diego, just north of BAJA "laud is out"
    Last week reading about KLR i watched a Video on the "Disheridiooo." think. The guy "sounds German in NZ" mention something on one of the Starter Gear shaft are going in TO FAHR to the Housing hole and can cause Problems.:deal
    #20