I am currently on a trip from Montevideo Uruguay through to the North of Brazil and I am stuck in Sao Paulo with a tricky ol carburetor.
BIKE- 2000 KLR 650 C (from what I understand there is no difference between the C and A model fuel system)
A little history...
This motorcycle I bought in Canada in September 2014 and drove down to Montevideo over the course of a year, during this time I had one carb service in Colombia (about half way down) and never had a problem with the fuel or carb system. I drove through countries with quite bad fuel (Bolivia, Peru, etc) yet from what I could tell this never posed a problem)
My bike remained in storage for 6-7 months and I drove it to Argentina and back with no issues, I then stored my bike for a further 8-9 months to begin my current trip.
Before leaving Montevideo, I had my carb cleaned and serviced. Around 1,200kms later, after parking my bike for around 2 weeks, I noticed fuel leaking out of the carb so I took it to be cleaned again. The mechanic told me it was a problem with the fuel in Brazil as I had just been using the cheapest fuel available. He installed an aftermarket fuel filter and told me I could keep using the cheap fuel as the filter would take care of the problem.
I drove like this (with the cheap fuel) for another 200kms or so without issue until I felt the bike surge and stop while in 4th or 5th gear as if it were running out of gas. I was able to start my bike again and drive off, yet the problem happened again around 20kms later and again another 30-40kms later. I switched to the more expensive fuel and the problem seemed to go away.
After some googling I found out that the KLR already has a fuel filter (or several) and my newly installed filter might be the source of this problem. I drove my bike a further 4-500kms (with one or two similar incidents) and parked it where I am now, in Sao Paulo with the plan of removing the fuel filter.
Now, it feels as if the carburator is dirty again. There was a slight fuel leak from the carb a few days ago (yet from what I can tell has now stopped) and I am unable to open the throttle without it cutting off. When it starts (which it currently wont) it will idle for around a minute or two before puttering and shutting off. I have removed the fuel filter and the problem is still there.
This would now be the third time in about 1500-2000kms that I would have my carb cleaned. What could be causing my carb to get so dirty? I was thinking it might be my fuel tank (which is plastic), seeing as I have been putting mostly crappy fuel in for some 40,000kms since Canada could this be causing my carb to get so filthy? Or are there other things I should be looking at? Is the fuel filter on the KLR inside the fuel tank? and what is the best way to clean it?
Hope I'm being clear enough, I appreciate any help you guys can give.
Ride safe everyone!