KLR650 (06) - Starter Relay Fell Off onto Chain!

[Kitimat KLR]

Not sure where to post this. I found that the Starter Circuit Relay (behind plastic cover LH side) had fallen down and was nicely wedged between rear shock spring and the drive chain ...slowly grinding away. Fortunately I was at home, back from a run. Ever tried push-startinga KLR?

So this is a word of warning to all - double check that the rubber cover is securely attached to the clip (zip-tie?)

Ref: Clymer Manual p.201-202 & Fig.40 item B

Some photos below (click images for more stuff)

Some questions: :help

1) Is the Starter Circuit Relay easy to find / replace? ...or do I need a Kawasaki dealer to get it?

2) Is anything else (electrical) likely to have died as a result of this?

Hope it's of interest - feedback welcome - Please!

 

[sparklr]

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Interesting dilemma, maybe this will help. Apparently the relay for your fan maybe identical to this one. Also read and damn lost it that there may be 2 of these relays on the same cover, and that one is used for the kickstand/clutch safety, could be bypassed and jumpered, somehow. Do you have two? I found it!

http://www.advrider.com/forums/showthread.php?t=357285

Hmm

http://www.klr650.net/forums/showthread.php?t=58483

This one sounds promising:clap:

http://www.klr650.net/forums/showthread.php?t=47827

Hope these shed some light on the situation.

Think I'll get a noose around that little relays neck, just to be safe.

 

[Kitimat KLR]

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sparklr wrote:

This one sounds promising:clap:

http://www.klr650.net/forums/showthread.php?t=47827

Thanks ...thats the one.. good researching...will try the "jumper" and try to find the fan relay and do a swap test as well to see if anything else is fried or ripped apart. The original is gnarled badly. I'll post another photo later & an update after the "tests"...it's got tram lines where the chain cut it up.

Anyone know what the spec is for this relay? Where can I get one (...apart from another KLR ) I don't trust myself with the "sidestand - down" but I'm usually a "clutch lever in" starter upper.

 

[sparklr]

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Fan and starter safety replacement
Toyota part number 90987-02004-83 is a plug-in replacement for these relays, for about half the price of the Kawi unit, and usually available from dealer stock. It is also listed as NAPA/Beck-Arnley P/N's BA2030055/2030055.

Perhaps this is useful. Alternatively, possibly a 12V automotive relay might work (Not sure if there are any NO or NC issues). I got a Bosch one from Napa, cheap too.

Guess what, they are closed today.

 

[Kitimat KLR]

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Thanks again ....I did the jumper wire fix ....it's alive! :bliss:

I used the identical fan relay (RH side near reservoir tank) to test the connections

Click on the photos in the above postto see more ...like most things, pretty simple when you've been shown how :shoot: (Sorry, Ican't seem to get photos to stay in a logicalorder)

:ted:Everyone should zip-tie this relay securely in place. It's not the sort of thing you want happening 100kms up the trail (...although I now know the fix)

This link is very good: http://www.klr650.net/forums/showthread.php?t=47827

Next jobs ...doohickey, sprockets and chain ...I wonder what will fall off next? (Note to self...buy more loctite - done!)

Update: Ordered part from NAPA ($23.59+tx) ...will update when it arrives