Won't Start in 1st?

[tashunka]

Over the last few weeks I've had a few issues where my KLR won't start while in 1st gear. Usually if I let the clutch in and out a few times and cranked it all the way in it would typically start. Not any longer. It won't start at all while in 1st now.

Is this likely a clutch adjustment issue or the safety switch would ya think?

I haven't noticed any performance issues with the clutch otherwise....

[joker650]

It's possable that the clutch is out of adjustment and is draging a little , preventing the proper cranking rpm.

It may also be the first sign of a weak battery now not having enough power to overcome theclutch drag.

When in neutral doed ot start properly?



Try adjusting the clutch cable and see if that works. If not, get the batterie checked out or just replace it. These batteries are quite small and may not last verry long.

My DR650 does not have a kick starter so to prevent any problems I replace the batterie every 3 years.

[tashunka]

It has absolutely no problem starting in neutral. I probably should have been a bit more clear.... it's not that it won't start, but it won't turn over at all. I have a feeling it may be the safety switch that prevents you from trying to start the bike while it's in first gear. But at the same time, if it's just that the clutch isn't quite adjusted properly, maybe it's just not disengaging the switch fully or something. Haven't done any clutch adjusting before and I don't want to make things any worse or further out of adjustment if that is indeed the problem....

[BMWNut]

If I can remember from my friend's KLR he had periodic problems with the clutch interlock safety. Check for a small switch on the clutch lever unit. It sounds like it's going.

If you feel like playing with it, there are only be two possible ways, closed or open.

[Backcountryboy]

This is a common KLR problem. It has been written up on a number of the KLR webpages. Have a look at this one http://www.bigcee.com/klr650faq.html#knownissues

I had the same problem and ended up disconnecting the Clutch start interupt switch. The bike now starts just fine with the clutch in, the challenge now of course, is that it will also start just fine in gear too! Much like the older motorcycles always did. After a couple of inadvertant lurches forward, you will learn to either start in neutral, or with the clutch in, or both, exclusively.

[tashunka]

PROBLEM SOLVED!

I went to check the adjustment of it and make sure it was good. Everything seemed fine there, so I figured there's gotta be a switch on here somewhere, chased the wires and as BMWNut pointed out, there's a wee switch built into the clutch lever housing. Pulled it apart and discovered the copper contacts were pretty corroded. Gave them a quick buff with a scotch brite, reassembled and she's all good now. Tried it a bunch of times and it worked 10 out of 10....

thanks for the help though guys, that's what I love about this place!

[Island Hopper]

I wouldn't recomend deactivating that safty switch because it also protects the starter from getting fried if you mistakingly push the button while at speed.

[sneakybc]

I just got my 02 KLR a bout a month ago with only 5500kms on it and already it started to intermittently start.

MMMMMmmmmmm, now what could this be I thought?

After some searching on some immensely useful KLR sites I found out that the clutch safety switch WILL eventually go. I printed off the instructions and photos and headed out to the bike for about a half an hour and did the fix by just taping the 2 connectors together instead of making a jumper and VOILA no more starting problem. I recommend the fix before you get stuck trying to figure it out on the middle of BSville, Madagascar! I would have done the kick start fix, but for some reason that safety switch doesn't work anyways!

Here's a good link:

http://www.klr650.marknet.us/safetyswitch.html

Cheers,

Sneaky

P.S. - that ride from Kamloops to Lillouette looks real good to me!

[tashunka]

thanks for the link Sneaky, Markent is a great resource...

I'll be doing both bypasses in my near future...

[joker650]

Glad ya got it going buddy

[Norm]

There are two schools of thought regarding the safety switches but having witnessed a horrific accident due to someone riding off with sidestand down I prefer to leave them. One solution is to wire in a DPST switch to allow the safeties to be ddisabled if desired but to allow them to operate normally. My switch is mounted into the solenoid switch cover on the left side frame. If anyone would like a copy of the proceedure, just email & I'll send it.



Norm