2006 KLR650 clutch problem

R

RileyW

Guest
I came back after a 500 km ride on my KLR, shut my bike off, next morning went out to start my bike, started fine, idles fine, then, pulled in the clutch, shifted into first and imediatly shuts off on me. There was no problems during the 500 km ride with my clutch, If anyone has any idea's how to fix this, please comment.

RileyW
 
J

jimmy sage

New member
imported post

imported post

hey riley does it stall as you let the clutch out as i was wondering if it has any thing to do with the kick stand safety switch
 
C

cathouse willy

New member
imported post

imported post

Riley It sounds very much like a sidestand contact issue, when the sidestand is down it disables the ignition coil in anything but neutral. These contacts are vulnerable to moisture and dirt. Check them first. They're a make/break contact so if they're dirty or ooa the brain thinks the stand is down and shuts you down. Hope this helps

Bill
 
R

RileyW

Guest
imported post

imported post

Jimmy, The bike stalls when i shift it into gear...I will have the bike in netraul...then i will pull the clutch lever in, its all fine...then i shift it into gear and it stall with the clutch it.
 
Big Booger

Big Booger

New member
imported post

imported post

Most likely side stand switch. If you connect the two wires going to the switch, this will bypass the side stand switch. Your bike will run. cost nothing. The switch is a safety so you don't drive away with the stand down. Be safe. Replace the switch when you can.
 
R

RileyW

Guest
imported post

imported post

Which two wires? i have one cable coming from the side stand up to a black shield, i take the black shield off, and theres a little device there that when i pull the kickstand down, pulls the device down, but when i pull the kickstand back up, the device moves very little. but i can still pull the device up with my hand and it comes up. but even with that all the way up, the bike still stalls when i put it into gear.
 
volcon

volcon

New member
imported post

imported post

The little device under the"black shield"that moves up and down is the side stand switch. There is a actuator cable that goes to the side stand andtwo wires on the switch itself.

First check that the electrical connectors/connections for the side stand switch andclutch switch are in place and fully seated.

Next step is to get a manual. The Clymer manual for the KLR650 is very good and a lot cheaper than a factory manual. Your local Kawasaki store should have one. Or, someone might lend you one.

It's unusual for the side stand switch itself to fail, it's more likely that the actuator cable is sticking. You can check this by removing the cable from the switch and allowing the switch to move fully up to about "1 o'clock". If this solves the problem and sticking cable is confirmed.

A failed switch is confirmed by joining the wires on the switch together after you have checked the actuator cable - if this solves the problem a bad switch is confirmed.

If the above steps do not fix the problem it's time tocheck the wiring andthe clutch safety switch.Or, better yet, follow the steps in a service manual to check the clutch switch and the side stand switch.

*SAFETY WARNINGS* If the side stand switchis bypassed the bike will start and runwhen it is in gear weather theside stand is down or up.If theclutch switch is by-passed the bike will start and run weather the clutch is pulled in or not and weather it is in gearor not even if the side stand is down.

:stupid:
 
R

RileyW

Guest
imported post

imported post

When i put the bike in gear(without the engine running) then pull the clutch in, i cant roll it back and forth...it is locked...
 
ktmken

ktmken

New member
imported post

imported post

put the bike in 4th or 5th gear and then rock the bike back and forth.Can you break the clutch free then?
 
ktmken

ktmken

New member
imported post

imported post

Put the the bike in 4th or 5th gear. Pull in the clutch and thumb the starter button. Does the starter try and break the clutch free or are you not getting any power to the starter.

I am trying to figure out if you have clutch plates that are stuck together or if you have a clutch lever or kickstand interlock problem.

I had a 640 that would do what you are describing. I would put the bike in 3rd gear and rock it back and forth with the clutch pulled into break the clutch plates free, and then it would start and go into gear just fine.
 
R

RileyW

Guest
imported post

imported post

I have not tried putting the bike in a high gear and braking the clutch plates apart, only tried in first gear with the clutch lever in and it will not rock back and forth...The bike will not start if the clutch is in, or the bike is in any gear...but this has been the same for a long time..usually i just leave the bike in netrual then start the bike, shift ETC...The bike will not start if the clutch is in, even if the bike is in netrual.
 
R

RileyW

Guest
imported post

imported post

Ever since i got the bike, i have not been able to start the bike while it's in gear, or if the cutch lever is pulled in...That would be the clutch safety device wouldnt it? I have a feeling it is both the problems, Clutch safety device is shoot(ever since i got the bike) and the clucth plates are stuck together.
 
R

RileyW

Guest
imported post

imported post

Just what i thought, it was both of the problems, clutch was stuck...and the side stand device is broken!:Xi put the bike in 5th gear, and rolled it with the clutch lever pulled...but it wouldnt move...so i really yanked on it and i got it to free itself...put it back into neutral and it starts, shift into first! and it didnt stall! :D...but it stalls when i put the kickstand down....and i can only start the bike when it's in netraul, and when the clutch lever is NOT pulled. Thanks for the help everyone.:D
 
tomcycle

tomcycle

Past President DSBC 2004 -2018
Staff member
imported post

imported post

I have been following this tread, and I thing I need some clarification

When you say it wont start, do you mean the starter motor does not engage or the engine turns over and wont start?

How many miles does the bike have on it. A well used clutch baskit will develop depressions that will hang the clutch plates in a engaged position, making it difficult to start in gear. (the starter motor engages and the clutch drags too much to allow the bike to start) Another sign of this condition is difficutly engaging the transmission from neutral, also if you have the bike in gear and the engine running the bike want to crawl forward.

But it does sound like one of the saftey lockout devices is screwy, bypass them to determine which one(s) are faulty.

Tom
 
R

RileyW

Guest
imported post

imported post

well, The starter motor will not engage when the bike is in gear, or when the clutch is pulled in. The bike has 18,700km on it. I can not start the bike in gear because the starter motor wont engage.
 
F

franhoser

Guest
imported post

imported post

you're clutch is fine. it's electrial. as stated above disconect the side stand switch and see it that resolves it. if not, take the bike and sell it and then buy a husky.
 
tomcycle

tomcycle

Past President DSBC 2004 -2018
Staff member
imported post

imported post

yup I will agree with the above, its an electrical problem

I am not sure how the starting interconnect works on a klr but I am sure it will be ez to disconnect everything to test. You will need a electrical diagram if your not sure what you are doing.

Personally I dont like the safetys on the bike, as they seem to fail in the most inopertune times. I only recommend that you bypass the safetys for troubleshooting only.

Most likely the sidestand switch, as stated earlier.
 
You must log in or register to reply here.
Top