KLR650 Only Thread......

Discussion in 'Thumpers' started by willys, Nov 19, 2011.

  1. andmoon

    andmoon Long timer

    Joined:
    Oct 28, 2004
    Oddometer:
    3,199
    Location:
    NJ exit 10
    Hey guys I am looking at an 09.
    The starter only works if the bike is in neutral. Is this normal? I would like it to work in gear with the clutch lever pulled in.

    Thanks. Don
  2. tigagreen

    tigagreen n00b

    Joined:
    Jan 29, 2012
    Oddometer:
    8
    Location:
    NEOhio

    It should start, with side stand UP. Safety switches on Clutch and side stand. (which both can be bypassed.)
  3. andmoon

    andmoon Long timer

    Joined:
    Oct 28, 2004
    Oddometer:
    3,199
    Location:
    NJ exit 10

    Won't start with sidestand up clutch lever pulled in and in gear. Stall bike and there is no quick recovery as the gearbox has to go into neutral before the starter will engage.

    Maybe the clutch safety can't tell if the lever is pulled in or not.


    Thanks.
  4. 8lives

    8lives Dharma Bum

    Joined:
    Jan 16, 2012
    Oddometer:
    2,027
    Location:
    Shasta County,Calif
    Has to be in neutral.
  5. ChromeSux

    ChromeSux Un-plated and Unscrewed

    Joined:
    Sep 1, 2008
    Oddometer:
    2,002
    Location:
    Lenoir City TN.
    I think i remember having this issue with a used KLR, either the clutch switch needs to be adjusted or, it was bypassed incorrectly, mine was bypassed incorrect, once bypassed correctly it would start with bike in gear and clutch pulled in.
  6. rodmuzwa

    rodmuzwa Been here awhile

    Joined:
    Jul 29, 2012
    Oddometer:
    174
    Location:
    Pinjarra, WA
    Ok. Managed to source a Harley carb slide for $58 from local HD dealer. If I replace the slide do I need to re-jet? And what is this 22 cent mod that everyone raves about? Should I also be doing this?
  7. GO_OUTSIDE!

    GO_OUTSIDE! dirty hippie

    Joined:
    Jun 29, 2011
    Oddometer:
    308
    Location:
    SF Bay Area California
    Dont bypass the clutch switch, clean it or replace it, it is just as easy as bypassing it. I have seen the results of bypassing it and if your parked in a row of other bikes when it happens, it will be costly and very aggravating for your fellow riders.
  8. Tsotsie

    Tsotsie Semi-reformed Tsotsi

    Joined:
    Nov 12, 2007
    Oddometer:
    2,303
    Location:
    South Texas
    No. You are using the same needle - that controls the mixture.

    On the US models the small idle air screw mixture screw is capped so you cant adjust it- EPA issue. By reming the cap one is able to adjust. richen up the idle mixture. I dont beleive that the Aussie models are capped.
  9. rodmuzwa

    rodmuzwa Been here awhile

    Joined:
    Jul 29, 2012
    Oddometer:
    174
    Location:
    Pinjarra, WA
    Thanks for that. So does that mean its simply a swap over and good to go?
  10. griffo1962

    griffo1962 Long timer

    Joined:
    Oct 24, 2006
    Oddometer:
    1,755
    Location:
    Carrara, Qld, Australia
    yep, but take care that the rubber is located correctly :evil
  11. XDragRacer

    XDragRacer Long timer

    Joined:
    Mar 25, 2009
    Oddometer:
    3,818
    Essentially, YES! Your replacement slide is essentially, "DIRECT EXCHANGE."

    The 22-cent mod consists of two elements; drilling the vacuum port in the slide to 7/64" diameter (in hope of enhancing throttle response), and shimming the needle (with one or two approximately 0.030"-thick washers, to fuel-enrich the air/fuel mixture from low through upper mid-range throttle excursion).

    Why fuel-enrich the mixture when dominated by the needle and neelde jet? Some believe the mixture is sub-optimally fuel-lean as-built, to insure conformance with emissions standards.

    Then again, I know of an '08 KLR650 with 55,000 miles of extensive northern and western hemisphere travel, with an absolutely stock-configured carburetor, and a happy rider! (Not I; but an inmate whose technical opinions I value.)

    The idle mixture screw adjustment (proposed starting point: 1.75 turns out, at sea level, stock engine) seeks to compensate for factory adjustment, allegedly skewed for emissions compliance.

    Your bike, rodmuzwa; whatever works for you, WORKS!

    Congratulations on scoring the Harley slide. <!-- / message -->
  12. rodmuzwa

    rodmuzwa Been here awhile

    Joined:
    Jul 29, 2012
    Oddometer:
    174
    Location:
    Pinjarra, WA
    Can I just take the time to say you guys on here are pretty bloody awesome. Amazingly helpful and very patient particularly with a n00b dumbass like myself. I'm very glad I bought a KLR. Thanks again to all who helped answer my stupid questions!
  13. 8lives

    8lives Dharma Bum

    Joined:
    Jan 16, 2012
    Oddometer:
    2,027
    Location:
    Shasta County,Calif
    Hey thanks XDragRacer for the quick,easy explanation on the carb mods,when I built my XS650 bobber I learned about carbs on motorcycles,I have been trying to leave the KLR alone but it sits in the garage screaming to be screwed with,it was good to hear of the guy with the 55000mile stock bike,but I'm a tinkerer so I know as soon as I yank that screw cover its no turning back,and at least there's only 1 Carb.
  14. 8lives

    8lives Dharma Bum

    Joined:
    Jan 16, 2012
    Oddometer:
    2,027
    Location:
    Shasta County,Calif
    And KLR's are very forgiving to us n00bs
  15. Aprilia

    Aprilia Long timer

    Joined:
    Sep 15, 2008
    Oddometer:
    1,075
    Location:
    Flagstaff, AZ
    Picked up my 92 in 2010 for $200. It had been left sitting in a backyard for over 12yrs with only 2450 miles on the odo. I was looking for a small project and figured this bike would be fun. The last few years I've found restoring bikes to be a fun hobby. I had just restored a 95 XR
    [​IMG]


    and figured KLR would be fun. I'd never ridden one and frankly never gave much thought to the KLR as spec's wise its a lousy bike...over weight, under suspended old old technology.

    Completed the restoration and took it for a few rides. For whatever reason I liked the bike. Something about being old school I guess. I did a few upgrades (brakes, suspension and motard wheels) and have since put nearly 40K miles on it. Even picked up an 08 last year though I must admit it mostly sits now. Still prefer the 92. The original paint is so ugly its almost cool now. Recently picked up a 94 Barbie for restoration. Its body paint is SO UGLY I'm not sure even I can find it cool in any way. lol. My better half stated she'd never be seen on the back of it.

    [​IMG]
  16. 8lives

    8lives Dharma Bum

    Joined:
    Jan 16, 2012
    Oddometer:
    2,027
    Location:
    Shasta County,Calif
    I'm a huge fan of XR400's,you did a nice job on that 1,the only thing that stops um is running outta gas.Buy your Wife a Harley,park her at the end of the pavement and tell her you'll be back when you get enough mud on.
  17. Aprilia

    Aprilia Long timer

    Joined:
    Sep 15, 2008
    Oddometer:
    1,075
    Location:
    Flagstaff, AZ
    Thats a 600 actually but essentially the same bike. I just picked up a Honda Aero 750 for $1200 with 1400 miles. Its sat for nearly 10yrs now. She'd look good on that one but I'd prefer she was on the back with me. :lol3
  18. 8lives

    8lives Dharma Bum

    Joined:
    Jan 16, 2012
    Oddometer:
    2,027
    Location:
    Shasta County,Calif
    Whoops,they look so close and I had 400 on the brain,XR's are tough bikes
  19. ANutt

    ANutt Keyboard Adventurer

    Joined:
    Jul 7, 2007
    Oddometer:
    438
    Location:
    Canton, GA
    Wow, talk about timing! I had this issue yesterday on my 2012 KLR. Nothing's been bypassed or adjusted. Any ideas what might cause it not to start in gear with the clutch pulled in?
  20. bdcorrigan

    bdcorrigan Been here awhile

    Joined:
    Nov 6, 2011
    Oddometer:
    650
    Location:
    South Of Portland Oregon in the Burbs
    You will not be ably to start the bike in gear with the clutch pulled in. You will have to bypass the switch in order to start the bike in first gear. I highly suggest doing this mod if you ride offroad.