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Discussion Starter #1
Ok so two questions here

NGK iridium plugs, i read it before on here but can't find it, what exactly do i need? i got hte NGK part but as far as the other stuff like the gap is what i have no idea bout.

Starter rebuild, I've tried finding information on this and only found stuff about people saying "well i did it" Where exactly is the starter? Im having a hot start issue where i hit the start button after shutting her down and nothing, not even so much as a click, first i thought it was my ignition switch so i bought a new one, even though it didn't fix the problem, the old lock cyl was about to crap out(it did after i took it out and started playing with it).

From reading my options to fix this problem are
-clean ignition switch(completely replaced problem still ensues)
-new plugs(going to do next soon as i find out the exact plugs i need)
-starter rebuild(have a kit on ebay in my favorites just have no idea where the starter is located at or even how to rebuild it since i can't find a wright up, sure i'll be able to figure it out if i can figure out where its located)
-new starter solenoid
-starter relay in the JB

After reading and talking with my dad im almost certain its the brushes going bad in the starter hence why im planning on doing the rebuild, BUT i figure i would go with the cheapest and easiest solution first which would be the plugs.
 

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if there is NO sound when you try to start it, look before the starter (electrically).

even if starter is shot to hell, you will still hear the solenoid clicking (its under right side cover).

I had intermittent issue like your hot start issue at one time, where it would not make an sound when trying to start. I determined that the relay inside the junction box was intermittent. that relay turns the power to the solenoid's coil on or off. basic operation is power to the start button (provided by ign switch, run/stop, and the various safety switches in the circuit) to activate the relay in the junction box. that relay supplies power to the coil of the solenoid, which in turn supplies power from the battery to the starter

I solved mine by bypassing the relay with a jumper wire (NOTE: you will by pass the safety switches doing the mod)
 

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ass hole extaordinaire
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i can rebuild the jb with new relays if you need i charge 50 bucks you pay the shipping to me and i pay the return shipping i can have yours fixed and back in the mail the next day
 

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Discussion Starter #5 (Edited)
About the gap, just got the plugs at auto zone and they said that i should check the gap on the plugs just to be safe so what should the gap be? checked the new ones and they are all .032 guess im good ot go since i found a thread that said .032-.036 is what you want.

@New rider
i may have to take you up on that.
 

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2014 KLR 650!
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If the starter turns the engine aver at all it's not the starter. The starter JUST rotates the engine. Nothing to do with ignition. So don't bother rebuilding that.
 

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Discussion Starter #7
If the starter turns the engine aver at all it's not the starter. The starter JUST rotates the engine. Nothing to do with ignition. So don't bother rebuilding that.
Well i put the new plugs in, and completely cold couldn't get it to start, not sure if i dont have em tightened down enough for if the problem has stepped itself up a notch, but with how it currently is and with my hot start problem im able to get it to start by throwing it in gear and rocking it, i figure it would be a good idea to get the junction box repaired, either i'll get the relays and do it myself or send it off the newrider, and its 20 years old might as well rebuild the starter. If all else fails and i still have the problem with new starter brushes and a rebuilt JB what should my next step be?
 

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Jack of all trades
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How old is your battery?
 

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Discussion Starter #11
Throwing it in gear and rocking and hitting the starter?
the start button, not starter. But yea i throw it in gear, let the clutch out and rock it, throw the clutch in and hit the start button and i can get it to start up, thats why im guessing more then anything its the starter, the brushes are probably heading south, and fast. And like i said its 20 years old so yea the JB may need a rebuild and even if it doesn't, new relays aren't a bad idea just to be on the safe side, but other than that im out of ideas.
 

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Discussion Starter #12
also this just occurred to me, the neutral light rarely comes on anymore, i read that the switch wire is "at the back of the engine" is it the greenish colored wire? could a corroded/dirty connection be the cause of this and some contact cleaner be the fix? or atleast part of it due to having to rock the bike in gear to get it started to me sounds like a classic starter going bad, but the N light not coming on while in neutral and not starting might be a secondary cause to this?
 

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The neutral sensor may cause this. If you are rocking the engine you aren't engaging the starter at all. Under normal operation the drive gear on the starter isnt meshing with the flywheel unless it is energized. Try cleaning the aforementioned contact point and see if it helps.
 

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Discussion Starter #14
The neutral sensor may cause this. If you are rocking the engine you aren't engaging the starter at all. Under normal operation the drive gear on the starter isnt meshing with the flywheel unless it is energized. Try cleaning the aforementioned contact point and see if it helps.
yea i just did that, cleaned the contacts at the clutch and both ends of the neutral switch and now at this current point in time starts up, shut her down and started her back up about half a dozen times, neutral light still isn't turning on though, i mean it does but when it wants to. I'll have to take her for a spin here shortly, get her nice and warm and see if she'll start back up.
 

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Discussion Starter #15
yea dirty/faulty clutch switch and a bad neutral swtich might be the cause of all of this, since i cleaned the clutch switch contacts i was able to start it up and i disconnected the N wire at the sensor and touched it to a engine bolt and the N light lit up so im assuming that means the neutral switch is bad. Hopefully this problem is solved, i'll probably still rebuild the starter(why not?) and probably send my JB off to new rider(can't hurt right?) for a rebuild but all seems good atm, just need to get a balaclava or a scarf or something so my neck doesn't freeze on the way to and from work!
 

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Discussion Starter #17
just for ****s and giggles if i really wanted to get an OEM neutral sensor, anyone have the part# handy or an aftermarket that works? don't now how i feel about getting a used one off ebay or something if i end up deciding "hey lets replace that!" same with the clutch nanny switch.
 

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2014 KLR 650!
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Would you please video rocking the bike back and forth and starting it? That will be a first for me.
 

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Giggity!
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Dude, You know I'm starting to part out the bike. I rebuilt my starter last year & I can give you an operational neutral switch too
$35 Shipped.
Let me know if your interested.

Also, as a side note, I don't believe you're supposed to adjust the gap on iridium plugs.
The tips are very delicate. If you adjust them, Please be careful.
 
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