Help get my bike running - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 25 Old 04-03-2011, 09:21 PM Thread Starter
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Join Date: Mar 2011
Location: Charlotte, NC.....Home is in my head
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Help get my bike running

I bought an 05 KLR a few weeks ago. I rode it for a day with no problems. Next time I rode it, I started having issues. I would warm the bike up and it would idle fine. Once I started riding, as soon as I got above 3k rpms, it would stay up there. When I pulled the clutch it would rev up to about 3500, and do the same if I put it in neutral. I thought it was the choke, as the cable wouldn't stay in the bar fitting. I did the .22 cent mod, and also broke the choke fitting at the carb. I pulled the cable choke off the bike and installed the klx plunger. I checked and the diaphram looks good. The bike is still doing it. I tried with the pilot screw turned out 1.75, 2, and 2.25 turns. It didn't change at all. It would stay running before, but now it revs and slowly revs down until it dies. I did some reading, and pulled the carb today. I thought the pilot jet could be clogged. The jet looked great, but I cleaned it anyway. Nothing was clogged. I also put about half a can of seafoam in a 3/4 full tank. I put everything back together. It warmed up and idled fine. Soon as I took off and got above 3k it started doing it again. Got back to my garage, and then I couldn't get it to start without the choke. As soon as I turn the choke off it dies. What is going on? Anyone have any thoughts? I also had an issue with fan, but that is fixed at the moment.
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post #2 of 25 Old 04-03-2011, 09:31 PM
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Simple stuff, first..

How clean is the air filter?? And yes, I'm serious..

After that, I'd check for an air leak on the carb boots for air leaks..

Odd progression of running issues has me confused..
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post #3 of 25 Old 04-03-2011, 09:38 PM Thread Starter
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Quote:
Originally Posted by Paper View Post
Simple stuff, first..

How clean is the air filter?? And yes, I'm serious..

After that, I'd check for an air leak on the carb boots for air leaks..

Odd progression of running issues has me confused..
I feel the same way. The air filter is a bit dirty, but not bad at all. I don't think that's the issue. I checked the boots and made sure they were good and the clamps are pretty tight. I don't know what's going on, so frustrated. I just want to ride the thing.
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post #4 of 25 Old 04-03-2011, 09:42 PM
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Without putting my hands on it, I'm at a loss.. I'm sure Tom and VA, and others will be along shortly to assist you.. I just can't think of anything that would cause those running symptoms..
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post #5 of 25 Old 04-03-2011, 09:58 PM Thread Starter
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Hope somebody can lead me in the right direction. Carb seemed like it would solve it, but maybe I made it worse somehow.
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post #6 of 25 Old 04-03-2011, 10:11 PM
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Have you tried running it with the fuel cap open to check the tank vent? You might also want to put some vacuum on the fuel valve to see if the diaphragm is working properly.
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post #7 of 25 Old 04-03-2011, 10:24 PM Thread Starter
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Originally Posted by Trundlebike View Post
Have you tried running it with the fuel cap open to check the tank vent? You might also want to put some vacuum on the fuel valve to see if the diaphragm is working properly.
Yeah, I tried it with the cap open. How do I put vac on the fuel valve? I'm pretty new to wrenching other than basic stuff.
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post #8 of 25 Old 04-04-2011, 06:25 AM
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Sounds to me like an issue with the throttle assembly, somewhere between the handle bar throttle and the slide. I would check that the throttle cables are well lubed and functioning properly. Disconnect the throttle cables from the carburetor, and observe the speed of return, and ease of return, of the throttle assembly when you open and release it. This doesn't strike me as a jetting or diaphragm issue. Without actually hearing, seeing and feeling what is going on at your end, most anything from the forum will be a WAG. [Wild a_ _ guess]

My loudest suggestion would be DON"T MODIFY ANYTHING ELSE UNTIL YOU GET THIS ISSUE RESOLVED.

This does not sound like a fuel delivery issue. It sounds like the RPM's rise when the load from the engine is removed, as it should. The problem, if I understand correctly, is that the RPM's don't drop when you release the throttle. If this is accurate, I would focus on the throttle components, which runs from the handle bar, to the needle jet.

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post #9 of 25 Old 04-04-2011, 09:14 AM Thread Starter
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Originally Posted by vatrader View Post
Sounds to me like an issue with the throttle assembly, somewhere between the handle bar throttle and the slide. I would check that the throttle cables are well lubed and functioning properly. Disconnect the throttle cables from the carburetor, and observe the speed of return, and ease of return, of the throttle assembly when you open and release it. This doesn't strike me as a jetting or diaphragm issue. Without actually hearing, seeing and feeling what is going on at your end, most anything from the forum will be a WAG. [Wild a_ _ guess]

My loudest suggestion would be DON"T MODIFY ANYTHING ELSE UNTIL YOU GET THIS ISSUE RESOLVED.

This does not sound like a fuel delivery issue. It sounds like the RPM's rise when the load from the engine is removed, as it should. The problem, if I understand correctly, is that the RPM's don't drop when you release the throttle. If this is accurate, I would focus on the throttle components, which runs from the handle bar, to the needle jet.
The slide was moving well yesterday when I had the carb off, and there is no sticking of the throttle at the carb. The throttle on the bar isn't sticking either. Could it still be throttle? Sorry to question you, I've just spent 7 hours trying to figure this out so far, and no luck. I don't wanna keep tearing stuff down unless I know it's a good chance that is the problem. I'm also pretty to new to all this, so I'm worried I could cause a new problem.
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post #10 of 25 Old 04-04-2011, 09:17 AM
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EasyRider84 -

What vatrader said.

I hope this is not too remedial - don't mean to sound condescending or anything...

Get on the right hand side of the bike and squat down so you can see the carb. Twist the throttle fully open and watch the mechanism on the side of the carb. Let go of the throttle. If it does anything other than slam closed, you've found the problem.

If that's not the problem you might have to pull the slide and have a look-see for binding.

T

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