Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Kawasaki

Kawasaki Kawasaki Tech Forum - For Questions specific and of interest to Kawasaki riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 29 May 2012
Registered Users
HUBB regular
Join Date: Mar 2012
Location: Toronto
Posts: 25
KLR Starter Stuck/Jammed?

After some searches on here I couldn't find the same issue that I'm having... so here it is:

Last week I replaced the Doohickey with Eagle Manufacturing's Doohickey and torsion spring. I've put about 350kms on the bike since with no problems but yesterday I started it up and I sounded like the battery was almost dead, but with a little choke it started up. I took it for a 30 min ride and turned it off. I tried to start it again and the starter wouldn't do it's job. My battery must be great since all the lights were full with no issues there, but the starter just wouldn't work. Have you ever held the chuck of an electric drill and heard that sound of the electric motor working fine but struggling to spin the chuck? That's the sound I'm getting. Here's what I think:

- The torsion spring has somehow popped out or jammed the large starter gear in some way.
- The starter is dead (but sounds like it has full power?!)

- Could the balancer chain be too tight? - Not sure if that makes sense...
- Could one of the starter gears have been moved out of place? (I double checked my installation and all was good...)

It really seems like a case of the starter being jammed up somehow. I jump-started the bike to get it back home, so at least we know everything else is good. I'll take the bike apart this weekend but some input from the family would be great!

Last edited by AVID; 29 May 2012 at 15:52. Reason: sp
Reply With Quote
Old 29 May 2012
Registered Users
HUBB regular
Join Date: Mar 2012
Location: Toronto
Posts: 25
I found this:

2009 KLR650 won't start - YouTube

This is the same problem I'm having on my 2001 KLR. I don't have a way to check the battery so I'll bring it by my mechanic friend tomorrow.
Reply With Quote
Old 30 May 2012
Registered Users
Veteran HUBBer
Join Date: Oct 2005
Location: Tappan, NY USA
Posts: 165
You might have better luck asking on KLR650.net or KLRWorld or even ADVrider.

You said you replaced the DOo, did you install all the gears properly? How about the spacers on the gears?

I would remove the starter first and see if it's turning. Just a thought, good luck.
John C.
Reply With Quote
Old 30 May 2012
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,470
First, remove the starter motor and text it using a 12V car battery. It should turn.. (careful though. Put it in a vice is you have one. They can jump with some force).

If that's okay, check the relay. It might only be intermittently switching.

Also, make sure the engine is turning okay by hand.

Turn the engine with the bolt that you would use to turn the engine when doing valve clearances.

If that turns okay then it's time to remove the side case and check the gearing and/or the clutch where the started motor is geared with.

You should easily find the problem if you check all these things...

This is only general advice. I can't picture the exact systems from memory.
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
Old 30 May 2012
Registered Users
HUBB regular
Join Date: Mar 2012
Location: Toronto
Posts: 25
Thanks guys,

I've posted over at KLR650.net I found a GREAT discussion that's leading me towards the fact that it may just be the battery... I hope.)

As for the installation - I double checked everything I did so I'm not going to open the case just yet.

I have a motorcycle mechanic friend with every tool you could imagine, so hopefully I can see him in the next few days to solve this issue. I'll post back here the results.
Reply With Quote
Old 7 Jun 2012
Registered Users
HUBB regular
Join Date: Mar 2012
Location: Toronto
Posts: 25
Thanks for everyone's comments. As it turns out, it was simply case a a low battery. A fine lesson learned: 'Check The Basics First'.
Reply With Quote

doohickey, starter

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
2008 Kawasaki KLR 650 - Adventure Ready (San Diego, California) Brienne TRAVEL Bikes for Sale / Wanted 0 20 Apr 2012 18:40
2009 KLR 685 in South America Flys Lo TRAVEL Bikes for Sale / Wanted 3 21 Mar 2012 20:02
WTB older KLR or KLR parts in Argentina flashG TRAVEL Bikes for Sale / Wanted 3 4 Feb 2012 19:32
2009 KLR 685 in South America Flys Lo South America 0 31 Jan 2012 00:13


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

HU DVD Autumn Special!

Take 40% off Road Heroes Part 1 until October 31 only!

Road Heroes features tales of adventure, joy and sheer terror by veteran travellers Peter and Kay Forwood (193 countries two-up on a Harley); Dr. Greg Frazier (5 times RTW); Tiffany Coates (RTW solo female); and Rene Cormier (University of Gravel Roads).

The first in an exciting new series, Road Heroes features tales of adventure, joy and sheer terror by veteran travellers."Inspiring and hilarious!"

"I loved watching this DVD!"

"Lots of amazing stories and even more amazing photographs, it's great fun and very inspirational."

"Wonderful entertainment!"

Check it out at the HU Store! Remember to use Coupon Code 'HEROES' on your order when you checkout.

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 15:25.