3500 RPM Madness! - 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 07-27-2013, 04:45 PM Thread Starter
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Join Date: Jul 2013
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3500 RPM Madness!

Wondering if anyone has experienced similar issues with their KLR.

http://www.youtube.com/watch?v=Ltptv...ature=youtu.be

Basically when I'm in gear and coming up to 3500 rpm my bike seems like its not getting enough fuel?
I have cleaned the air filter, I am thinking im going to have to take the carb off and clean the main jet.
Does anyone think it could be an issue with the petcock at higher rpms?

Last edited by Tom Schmitz; 07-27-2013 at 08:08 PM. Reason: More Info
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post #2 of 26 Old 07-27-2013, 07:30 PM
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kevinm219,
Have you had the top off of the carburetor? Maybe you pinched the throttle slide diaphragm upon re-assembly? Creating a vaccum leak.
More info will help, what maintainence or repairs have you recently done?
pdwestman
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post #3 of 26 Old 07-27-2013, 07:33 PM Thread Starter
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I haven't even touched the carb yet, I took the seat off to get a better look at it and noticed the bike is missing the hose for the rear tank drank. I'm pretty sure that's been missing since I bought it though and it has performed fine.

I haven't changed anything on the bike since I bought it and I was driving it to work one day and It started to act like that. I thought I was running out of gas so I went to Res and the problem followed.

I'm starting to think I should pull off the petcock and inspect it however it happens exactly at 3500 rpm in any gear.
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post #4 of 26 Old 07-27-2013, 09:26 PM
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Quote:
Originally Posted by kevinm219 View Post
I haven't even touched the carb yet, I took the seat off to get a better look at it and noticed the bike is missing the hose for the rear tank drank. I'm pretty sure that's been missing since I bought it though and it has performed fine.

I haven't changed anything on the bike since I bought it and I was driving it to work one day and It started to act like that. I thought I was running out of gas so I went to Res and the problem followed.

I'm starting to think I should pull off the petcock and inspect it however it happens exactly at 3500 rpm in any gear.

The carb works on throttle postion not RPM. So if it indeed happens at 3.5K rpm regardless of what gear your in then it's more likely an electrical problem. Sometimes you can see arcing in the dark. Look around the coil and spark plug lead areas. May need to pull the tank to check the harness for shorts and clean the connectors.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #5 of 26 Old 07-28-2013, 08:50 AM Thread Starter
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Alright well.. Just to clarify a few things up. The video is the only thing I could find that replicates my problem somewhat.

When im in neutral I can bring the bike up to 5k rpm no problem. However.. 1st through 5th is the problem of when I hit 3500 RPM it starts lugging and bogging hard. The rpms start going wonky.. I am leaning toward the fuel starvation.

I took the hose from the petcock to the carb off at the petcock end and switched it to the off position. The bike was not leaking fuel. This doesnt mean that the diaphragm is beaking down inside the petcock. I do not have an inline fuel filter which is what I'm going to be doing on Payday as well as taking the carb and petcock off the bike as soon as I burn most of the gas.
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post #6 of 26 Old 07-28-2013, 10:35 AM
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If your bike is acting like the one in the video, I agree with Spec, It doesn't sound like a fuel problem to me. There is a reserve of fuel in the float bowl. This would need to be consumed before the engine would falter. The misfiring would be more random vs rpm and would not be immediate after firing the bike and revving up to 3500+ rpm.
I too would be searching for an electrical short or fault.

There have been issues with the fuel petcock partially failing though, where the valve wasn't opening fully while riding, causing fuel starvation. This would be more random vs RPM, not occurring at a specific RPM each time. It would occur more in time with engine load ie:not occur during light load and showing up during heavier loading such as climbing a slope.
As to inline fuel filters....I just found the factory inline fuel filter on my 2011. It is a tiny screen filter INSIDE the plastic inlet fitting on the carb. The part the fuel line connects onto. I was not aware it is there and only found it by accident when rerouting the fuel hose while installing a manual Yamaha Raptor petcock to replace the vacuum petcock.

Hope this helps!....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!

Last edited by justjeff; 07-28-2013 at 10:44 AM.
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post #7 of 26 Old 07-28-2013, 10:43 AM Thread Starter
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Alright thanks for the tips, I was trying to readjust my clutch cable because it has a lot of play before it would grab..

Took it for a test ride and its even worse, 1st gear your lucky if it doesnt stall now.
I did manage to get it into 2nd but by riding the clutch like noones business.
In 2nd it is happening a lot sooner now like around 2500 3k rpm.
It Died on my probably 10 times just trying to go around the block!
What have I done haha.
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post #8 of 26 Old 07-28-2013, 10:49 AM
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Does it still start to falter at 3500 rpm? Will it still rev higher while in neutral or with the clutch in?
jj

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #9 of 26 Old 07-28-2013, 10:52 AM Thread Starter
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Nope, Now with the clutch in I can barely rev it at all.
It dies even with the clutch in and Reving it to like 2k..
I was lucky to get it back into the garage.
When im in neutral and take off the choke im sitting at 1100-1300 rpm and I can rev it to 5k + without hesitation.
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post #10 of 26 Old 07-28-2013, 10:59 AM
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You haven't been riding with the choke ON have you?
jj

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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