20 Most Recent 2003 kawasaki KLR 650 Questions & Answers

sounds like there is a wire that has been exposed and shorting out . as electricity flows through wires they heat up. as temp goes up the insulation around the wire gets soft so if wire gets pulled on or tugged on and there is a sharp metal edge it can cut through insulation and cause a short making certain items turn off.(id say if that's the problem it most likely to be around front of gas tank area. even the slightest indication of a wire that has had the insulation pinched or rubbed off take some electrical tape and apply around compromised area

Kill switch is in the run position ... ???

your problem is ether the switch itself or the single wire connector is loose in the switch located left side of the engine under the chain cover.

First, do you have spark at the spark plugs? Make sure to remove the spark plugs, lay them,one at a time, on one of the engine fins so it will have a good ground then crank over the engine.There should be a strong blue arc between the electrodes.
Next, make sure the carbs have fuel. You can place a small container under each one while loosening the drain screw on the bottom of each float bowl. If there is fuel there and it runs good when it does start the next thing is to look at the carb rubber intake tubes. Is there any indication of fuel (wet spots) between the intake tubes and the head? If so, it is drawing in air at that point which would make it hard to start.

I think you have a fuel obstruction.

Carb needs to be removed and thouroughly cleaned.

could be spring is weak are cable is frayed

fuel , spark , timing

Check battery and battery connections are clean (wire brush them) and tight.

check the kick stand switch, i fixed a bike that had the same problem and it turned out to just be the switch

Is it possible your clutches are so warn they do not engage?

uas a chaine tool.u can find one at your local out door moter sport store or napa should have one cheapper.

http://www.bikebandit.com/houseofmotorcycles/1999-kawasaki-klr650-kl650a13l-ca-frame/o/m3668sch70837#sch65882

If the problem happens while cruising at a steady speed while driving down the road you are having an issue with an intake manifold air leak or an issue with the vacuum diaphragm in the carburetor top (stretched, cracked, pin hole, etc). From the brief description you give (and the fact that the dealer adjusted the clutch cable), I assume you are dealing with an clutch that is not fully engaging when you shift gears. If what you are experiencing is the engine revving/slipping for an instant when you shift the problem is a bad clutch cable. The cable is binding for an instant allowing the motor to slip/rev for a moment before fully engaging. To check this unhook both ends of the cable, grab the end of the cable with your fingers, and slide the cable back and forth. If it binds the tiniest bit , replace the cable . Replacing the cable should fix the slip/ rev you experience when you shift. To unhook the cable from the bars turn the adjuster nut all the way loose, turn the slotted adjustment screw all the way into the perch, line up the slots on the screw and the nut, use the cable slack to pull the cable out of the perch and unhook it from the lever slot. On the engine simply slide the end out of the slot on the lever holder.

LOOK on the bottom of cylinders it will tell tell you how many cc MOPAR KENNY

There is usually a tag located on the frame. The most common place I have seen it at is on the front of the frame where the front forks attach to. If the bike has a front fairing the tag might be somewhere else on the frame or the fairing might have to be partially removed to see it.

If the battery is good you may want to inspect the wiring towards the switches on the handle bar. These wires are grouped together, so it is likely that both component may be affected. The other item is the switches. Check for worn out wires, terminals or loose connections. Other than that have the relays tested. It may be bad relays.

Below is a guide on how to test your relay.

http://www.kawiforums.com/how-tos-faqs/151951-test-relay.html

Hi, you most likely have a fuel shortage or excess air problem, you didn't mention the year of your bike but, -check fuel pump and fuses. -sounds like plugged main jets or jet tubes in the carbs. -Could be a plugged or faulty fuel petcock valve. -Check if you have a good flow of fuel to the carbs. Check fuel filter, carbs or fuel injection. -try draining the float bowls, could be water. -check around carbs intake for air leaks, might be sucking air instead of fuel. Try spraying some carb cleaner or wd40 around the carb tubes and see if the engine speed changes. -change spark plugs. -if it is fuel injected, a dealer may be able to check fault codes.

http://www.bikebandit.com/houseofmotorcycles/1989-kawasaki-motorcycle-klr650-kl650a3-us/o/m3676#sch61079

Here is a link to a schematic showing you the alternator. Check Rickystator to see if they might have one for you.