Sam and I tried to join my SOS sisters for a Sunday ride and
lunch. We took the Thruway to the
meeting spot….and my bike started having the EXACT same issue at nearly the
EXACT same spot as a few weeks ago when I was heading out on my solo trip.
In fact, I only made it about a mile farther than last time –
which at least got me onto the Waterloo exit ramp.
When we pulled over, I did a quick check of the bike. At first I thought to there was another airbox
hole, but I was mistaken (I was looking at previous melting). At this point, I am 99% sure that the issue
is electrical, not related to fuel/ air.
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| This is Paracord - don't leave home without it! |
Sam and I discussed our plan of action. I had a hank of paracord and Sam knows how to
make fancy-schmancy knots, so we decided that Sam towing me off the Thruway
with the Strom would be the easiest thing to do.
But if I can’t get the bike started, what happens then? Sam’s truck blew a
strut Friday – I was concerned that it would be dangerous for him to go get the
trailer to take the bike home.
I called my friend Terry to run the blown strut + trailer issue by him. We then talked through the bike issue – we were both on the same page that the issue is electrical. I already had a possible problem in mind, and he gave me a few others to look for.
Both Terry and I felt that when I removed the tank and pulled the carb, I moved whatever was causing the issue, which allowed the bike to start.
I called my friend Terry to run the blown strut + trailer issue by him. We then talked through the bike issue – we were both on the same page that the issue is electrical. I already had a possible problem in mind, and he gave me a few others to look for.
Both Terry and I felt that when I removed the tank and pulled the carb, I moved whatever was causing the issue, which allowed the bike to start.
Fast forward half an hour, and the KLR and I are back in the
same EXACT gas station and parking spot the tow truck left us in a few weeks
ago. I take a few minutes to message a
few people, feel sorry for myself, hydrate and think about what I need to do.
When I had the bike apart last week to clean the carb, I
noticed a hose from the air injection system was touching the spark plug wire.
I moved it and checked the wire, no evidence of arcing. I had already found a
huge hole in my airbox, so I wasn’t looking too hard (stupid me). I tucked the hose so it wasn’t touching the
wire and moved on. After replacing the
airbox, the bike started – so problem solved, right? Well, maybe not.
I stripped the body panels and tank from the KLR and went
right to the spark plug wire. The AIS
hose was back against the spark plug wire.
I moved it…and with the sun off to my right…clearly saw a flaw in the
wire jacket. Huh.
I tucked the hose away from the wire, and the bike started
right up. I put a few layers of electrical tape on the wire to eliminate any
issue with the hose contacting it, confirmed the bike would still start and put
the tank in place. Bike starts, but
stumbles and dies when I let off the throttle. Okey doke.
Removed the tank again, confirmed bike doesn’t start. Move
the hose, bike starts. Aha, progress!
Whip out the zip ties (all good KLR owners carry them), zip tie the hose out of the way, confirm bike starts.
Whip out the zip ties (all good KLR owners carry them), zip tie the hose out of the way, confirm bike starts.
Put tank in place, confirm bike starts.
Hold the throttle at 5000 rpm for 20 seconds to see if the engine misses
– nope, running beautifully.
Bolt everything back on and off we go. I rode the entire way home in a too low gear
to mimic the high RPMs of highway travel, trying to stress the bike. No issue...yet....
I will replace the spark plug wire, remove the useless
AIS, then do another nice long test ride at high RPMs. I had intended on removing the AIS when
I upgraded the piston last year – but didn’t (stupid me x2). I will also check over the wiring harness
again, just in case…
