04 KLR 250 Trouble shooting?

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Old Aug 30, 2013 | 04:18 AM
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Question 04 KLR 250 Trouble shooting?

i have an 04 KLR 250. with about 10000 miles. and my problem is: when i start the bike in neutral. (or any gear) i have to pull the clutch lever in, when its running in gear if i let out the clutch at any RPM the engine instantly goes to 0 RPM and dies. the bike wont even lurch forward. so i basically cant let the clutch out in gear. i can let it out fully while in Neutral and the bike wont die. My clutch was needing replaced. but it wasnt slipping yet, is this a clutch safety or an electral issue or do i simply just need to change the fibre plates?? please help me out.
 
Old Aug 30, 2013 | 07:33 PM
  #2  
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Originally Posted by MotoGuy
i have an 04 KLR 250. with about 10000 miles. and my problem is: when i start the bike in neutral. (or any gear) i have to pull the clutch lever in, when its running in gear if i let out the clutch at any RPM the engine instantly goes to 0 RPM and dies. the bike wont even lurch forward. so i basically cant let the clutch out in gear. i can let it out fully while in Neutral and the bike wont die. My clutch was needing replaced. but it wasnt slipping yet, is this a clutch safety or an electral issue or do i simply just need to change the fibre plates?? please help me out.
Hello. Sorry to hear of your situation. I think it's a simple fix though. I just hashed out a response to a similar problem posted up here yesterday. I'm going to take the chicken sh_t route and cut 'n paste the response here:

Please don't feel insulted if my questions seem mundane, but diagnostics over the internet are difficult at best, and by not asking critical questions, very simple solutions are overlooked and I look like a dumbazz. I try to avoid that.

1. Is the side stand up when you are attempting to engage clutch?

2. If so, check the plunger on the side stand switch. Make sure it isn't froze up or bound up from road grime / chain lube. WD40 works well to clean and lubricate the switch plunger.

3. If you still have no joy, find the wires leading to the side stand safety switch, and identify their colors. Should find two Green/White and Black/Yellow wires. These wires should be running down the frame tube. If they will unplug [bullet connectors] at the switch, pull them there, otherwise, follow the wires up the tube and cut them and connect the Green/White wire to the Black/Yellow wire to make a complete circuit. See what your bike does then.

Safety switches are on the bike for a reason. If this solves your problem, you might want to do what is necessary to make the safety switch functional again to prevent an accident take off with the side stand down. I have some nagging sense of responsibility to point that out.

Please let us know what develops, and good to see you here!
The KLR250 has a couple of safety switches that can be problematic if not properly maintained or become worn from use. One is the clutch safety switch, located on the bottom of the clutch mounting perch up there on the handle bars. It acts as a STARTER INTERRUPT [even in the absence of a magic starter button], and won't allow spark to the plug if there is not a completed circuit at the clutch safety switch. Your bike starts, so we can rule that one out. The other usual suspect is the side stand safety switch. It acts as an IGNITION INTERRUPT, cutting power to the engine if there is not a completed circuit for the side stand. That matches the description of your dilemma. You'll find the switch on the top end of your side stand.

 

Last edited by Fuller_Malarkey; Aug 30, 2013 at 07:39 PM. Reason: aw kin spel. aw kant type
Old Aug 30, 2013 | 10:51 PM
  #3  
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got it! so i discovered that the previous owner already bipassed the side stand safety. and the wire had corroded through. all patched up now. thanks for the advice. now... on to replacing my clutch. haha
 
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