Broke down - 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 26 Old 04-30-2013, 06:07 PM Thread Starter
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Join Date: Oct 2012
Location: Columbus IN
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Broke down

On the way home tonight ,sat at the lights and the bike stopped running , I hit the start button it rolled over ok but would not go.
Checked the fuel and there was plenty there, pulled off the vacuum hose then the fuel hose, no fuel came out.
Shook the bike back and forward ,hit the start button it hunted then fired up and ran in a fashion then stopped , tried again and it started with the throttle open closed the the throttle and it sputtered with a bit of black smoke out of the exhaust then died (repeat)
Eventually it ran enough to get me home if I held it at 2000 revs at the lights

It is a 2000 with 8000 miles on the clock

Any help will be appreciated

Thanks
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post #2 of 26 Old 04-30-2013, 06:19 PM
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Tiptoes -

Some simple things to start with:

You could have a venting issue with the tank, meaning the tank vents that are in the cap are stuck and not allowing the tank to vent. That will build a vacuum in the tank and not let the gas out. You can check for that by running with the filler cap open. If it runs OK with the filler cap open, you may need to attend to the vents.

The petcock is vacuum operated and the vacuum valve may have gone south. You can test for that by disconnecting the fuel hose and directing it into a container, then apply a vacuum to the petcock's vacuum line. That is best done with a separate length of hose that you can suck on. If gas doesn't flow from the petcock in a good solid stream, suspect the petcock. Either rebuild or replace. If a replacement is needed, consider a non-vacuum petcock like the Raptor 660.

The carburetor's inlet valve may be stuck or sticky. This is harder to diagnose without some way to provide constant vacuum to the petcock, but what you should try and do is open the drain at the bottom of the carb and see that fuel comes out. If it doesn't, rap on the side of the carb bowl with a screwdriver handle; that may allow the valve to open and fuel to flow. The fix there is to remove the bowl and float assembly and refresh the valve needle.

If the above seem all OK, you may have an ignition issue.

T

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“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

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post #3 of 26 Old 04-30-2013, 06:32 PM Thread Starter
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Thanks Tom
Just one thing I did notice or heard was the gas tank squealing when I went into the garage the night before.
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post #4 of 26 Old 04-30-2013, 06:36 PM
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OK, those would be the tank vents.

Let me find a good thread for you to look at.

OK, here's the best write-up I've seen on repairing the vent seals, it's over at .net.

This one simply shows how to remove them, it's over on klrworld.

Before digging into them, you'll probably want to take a ride with the cap open to see if it cures the problem.

T

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 04-30-2013 at 06:46 PM.
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post #5 of 26 Old 04-30-2013, 07:06 PM Thread Starter
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Opened the cap ,bike stated up and ran for 30-45 secs ,then stopped
Removed the fuel hose from the petcock, removed the vacuum from the carb sucked on it and gas flowed freely.
Installed everything back , started the bike up ran 30secs and stopped

So is it new petcock I need
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post #6 of 26 Old 04-30-2013, 07:42 PM
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No, it sounds like the petcock is good and the problem is down stream from there.

Without doing anything else (now that she's stopped running), try these steps:

Unscrew the drain screw (2 or 3 turns; no need to remove it completely) on the bottom of the carb. A bowl's worth of fuel should run out. If no fuel comes out or if it dribbles rather slowly, the inlet valve is wonky.

If fuel does flow out, suck on the petcock's vacuum tube; more fuel should flow out. If it works that way, it's not the inlet valve.

Also, make sure the carburetor vent line has not become clogged. On a 2000, it's the clear line that runs from a plastic elbow on the carb and down the back of the frame, exiting near the front of the swing arm.

T

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #7 of 26 Old 04-30-2013, 08:44 PM Thread Starter
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Guess what I am doing tomorrow ha ha
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post #8 of 26 Old 04-30-2013, 11:53 PM
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Quote:
Originally Posted by Tom Schmitz View Post
OK, here's the best write-up I've seen on repairing the vent seals, it's over at .net.
Holy moly, I had no idea the cap was this complex. Silly me.

With all due sympathies to those with broken bikes, I love threads like this. I learn so much!
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post #9 of 26 Old 05-01-2013, 12:31 AM
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Yeah, I found that when I was looking for pictures of the cap dis-assembly so that I could take mine apart and make the lock and latch work smoother.

The author is a good wrench who I first ran into over on the Yahoo Groups DSN_KLR650. He's solid.

T

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #10 of 26 Old 05-01-2013, 05:47 AM Thread Starter
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Undone the drain screw and fuel ran out freely after 1 turn ,I did not check the vacuum hose , and the clear plastic tube looked ok
Also in my original post I said I saw black smoke come of the exhaust just as the bike spluttered to a halt ,well I noticed the pipe was quite thick in soot ,it has always been a nice light brown ?
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