start button intermittent
Posted: Tue Aug 23, 2011 10:40 am
I have a Suzuki DR200 that had a similar problem. It ended up being the
kickstand switch. I put the stand down and kick it back up and it starts. My
brother-in-law had the problem with his kickstand. We were motorcycle camping,
but it was only a couple minutes of worry.
Patrick
________________________________
From: "k650@..."
To: JWF ; DSN_KLR650@yahoogroups.com
Sent: Tue, August 23, 2011 2:36:35 AM
Subject: RE: [DSN_KLR650] Re: Start Button Intermittent
I. The only function of the starter circuit relay is to allow the addition
of the safety switches. If you bypass like Marknet says the required ground
for the ignition has to travel from the relay up to the handlebar switch and
back again to the relay which can also fail. Removal of the relay
eliminates the possibility of the relay failing and removes the wire loop to
the handlebars from the circuit. This is the best way to bypass.
II. Battery tests out good.
III. This was your most likely culprit.
IV. Good job. I would like to add if you did not do so already a good
flush of the starter button with electrical contact cleaner once in a while
is good practice. If you ride in a pack of riders on a dusty trail the
airborne dirt particles can enter and foul the contacts.
Walt
-----Original Message-----
From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On
Behalf Of JWF
Sent: Monday, August 22, 2011 18:06
To: DSN_KLR650@yahoogroups.com
Subject: [DSN_KLR650] Re: Start Button Intermittent
Here's an update for those as can stand it.
I. Starter circuit relay: Couldn't test it, it isn't there. The
female plug is jumpered. Does this have to do with the clutch "safety"
being disabled? I found the relay in the hellbox, marked "starter/clutch
relay". But the identical relay behind the coolant reservoir seems to be
the fan relay, not the clutch. And the clutch safety disable drlll at
http://www.klr650.marknet.us/safetyswitch.html> doesn't involve the SC
Relay at all. So I'm confused.
II. Battery test (thanks Mr. Khoury for the easy instructions): it
tested at 12.25 V with key off, 10.5 while cranking, after a night on the
Battery Tender. Borderline I guess, and if it's not holding a charge it
would have been lower than that when the starter button failed last time.
But before that it worked @50 times over six days, and the battery hadn't
been on the Tender in weeks. Yet again, I'm ashamed to say the bike was
badly stored for three years, battery in place and no charger connected.
And yet yet again, it started first crank when I finally rolled it out.
It's sealed, no fluid to check.
III. Starter relay: Per da Vermonster's tip, the plug came apart
suspiciously easily. The holes in female end seem bigger than the pins in
male end (story of my life). I cleaned the plug and used a lot of
dielectric grease, then tested the relay: ok. On reinstall I tiewrapped
the plug onto the relay.
IV. Per general consensus and common sense (not always the same), I
went more thoroughly through all (well, most) connections on the bike,
cleaned, d-greased all. They were VERY dusty, but nothing broken as far as
my eye could tell.
I wish I'd been more scientific, tested the starter button before and
after working on a given component, tested a component before as well as
after working on it, and so on. All I know is that after doing all this
stuff, it does start. Til next time... But hey, when it conked out in the
Co-op lot saturday night, a homeless guy gave me a push. I gave him five
bucks he didn't ask for, got invited to visit his car/home anytime, and I
still got to the party before the beer in the tank bag got warm.
PLUG FOR CYCLEPEDIA: Within hours of my asking, they added a photo of the
"starter relay and starter circuit relay". -JWF
--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote: > > > > --- In DSN_KLR650@yahoogroups.com, "JWF" wrote: > > > > Thanks for all the tips. I didn't meter-test anything, I just went over all the connections. They were DUSTY! I un-plugged plugs, disconnected leads, sprayed 'em with quick-dry contact cleaner, dielectric-greased 'em, hooked 'em all back up and I haven't able to recreate the problem since. If it does recur I'll do the tests suggested. Thanks again- JWF > > > > It would certainly be helpful if 'use-guys' quit writing about such problems. Seems my 98 bike has been reading the mail and wants to play along as well. I was getting along JUST fine until you chuckle heads starting whining about your bike not starting. > > Actually, I think this is a seasonal thing: all these starting issues center around those who are committing KLR adultery--looking at the Milwaukee chrome pirate ships pass through and they 'wish' they were heading for the holy city instead of required to love some 1976 wonder of technology called a KLR. They have been lusting after some of that 1950 technology of chrome and noise. Sigh. Will we ever learn...? > > Could I leave well enough alone? > Oh, no. I had to go tell my girl, > 'You would never do a thing like that to me, would you?' > 'Leave me stranded without a hope? Other than a steep hill for a bump start?' > Being the strong silent type with a std piston and original tweeting muffler, I got a look of indifference that only 85-octane gas at 6000 ft. could produce. > > And wouldn't you know, this is the second year in a row this girl has done this to me during the holy week of Sturgis...is there a connection? Last week riding with a posse of KLR riders during bike week, the start sequence became intermittent a couple of times. The 'local wisdom' suggested, that #$*@! start switch was acting up, just like on their bikes. Not my bike. > Since it was a relatively new switch quadrant, I didn't think so...ultimately, it started, and never let me down. > > Then, yesterday, when I needed my lady for a therapeutic ride up Vanocker Canyon in the beautiful Black Hills...full battle KLR gear = ATGATT--and as sweat is starting to soak my shirt inside the mesh jacket > Push the button to start and nothing. sigh. > I look down at the front tire and the bike is READING the DSNKLR650 posts on a KINDLE! > About how not to start! > I raise my voice: > KNOCK that OFF! > > hmmm. > Houston: we have a problem. > Off come the jacket, coat, and helmet. > Kick a rock for good measure. > Having just moved and amid all the chaos that creates--I have stumbled onto a moment of good fortune. Just that morning, I had located some garage chemicals that will help. maybe. > > Here it is: electrical contact cleaner "not recommended for broccoli" > 'Requires adult supervision." > Great. > I go get my 15 year old so I won't hurt myself. cough. > What ever will they think of next.... > > So, spray contact cleaner in the switch housing. > Splash some on the gas tank for good measure. > Miss getting it in my eyes. > Note to self: Do not look down the length of the straw while aiming it into the switch housing. You 'might' get an eye full.... > > Hit the start switch. Nothing. > Yes Virginia, the key is on and the kill switch in 'ON'. > > Houston: we still have a problem. > Note: clutch safety and side stand disabled. So, that ain't it either. > Kick another rock. > > Remove the black cover that hides the solenoid; > Check the blade fuses; push-pull-poke around and now?--it starts. > hmmmm. > Not sure what I did, but never argue with success. so last night.... > Re-read the post while the bike is NOT looking over my shoulder nor can she hear me talking to the computer screen. > > hmmm. > It had multiple restarts, multiple times without fail. > hmmm. > Houston: never mind.... > Starts several times today, then it must have remembered that it wants to take another nap. > = aborts the start sequence again today. > =won't start. > grrrr. > (good bright light, loud horn, fuse good.) > > hmmm. > What did dat-brookline bumkin say? = guymanbro, tumu, Vermonster > He say: > Push the starter button and one finger massage the two-wire on the solenoid--whatdatya know: the lady wakes right up. > At least, it is now isolated to the two wire. > And a salt water bagel with LOX and black coffee. > maybe. > > Will pull the black cover again tomorrow and give a good cleaning to the two-wire that activates the solenoid. > > Last Aug, the girl did this to me 30 miles outside of White Sulphur Springs, MT. Finally, we got her started, moved to a garage and cleaned the solenoid contacts then as well. Little di-electrical grease and another 5K smiles without a problem; until bike week. > > Maybe, its just something this bike likes to do...pretend it is a Harley. Both instances began during bike week. > Yeah, that's it. > Bike week blues. > > Maybe I should ask for Fred for one of those new sensors that will sense `LOW': dielectric grease on the solenoid. I bet there is not a single person out there with that farkle.. > > revmaaatin. > > ps: thanks LIST: to all that reported their starter problems and those that offered advice. > It actually made my life a lot easier. smile. > I now have to figure out where I am going to put the LOW dielectric grease indicator. > ------------------------------------ List Sponsors - Dual Sport News: http://www.dualsportnews.com Arrowhead Motorsports: http://www.arrowheadmotorsports.com List FAQ courtesy of Chris Krok: http://www.bigcee.com/klr650faq.html Member Map: http://groups.yahoo.com/group/DSN_KLR650/app/peoplemap/view/map Group Apps: http://groups.yahoo.com/group/DSN_KLR650/grouplets/subscriptionsYahoo! Groups Links [Non-text portions of this message have been removed]