HELP! 2002 KLR is dying.. - 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 11 Old 09-23-2013, 07:52 PM Thread Starter
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HELP! 2002 KLR is dying..

I rode my 2002 KLR 650 to work today (about 10 minute ride) and it was running fine. I rode it home and it was still running fine. I got changed and decided to go out for a little ride and as I was riding along on the highway, climbing to higher and higher speeds, the bike started to lose power and before I knew it it was bogging down with every twist of the throttle.

I pulled off the road and pulled the clutch in and the engine died. I tried to start the bike with no luck. After maybe 2 minutes I put the choke on and it started right up! I started to ride home and the bike seemed to be running fine so I rode around town for a little bit and it happened again, this time at a much lower speed (30 mph). I pulled off to the side of the road and the bike wouldn't start no matter what I tried. After about 20 minutes I pushed the bike home, stopping intermittently to try to start the bike...no luck. I got home, put the bike in the garage and just for kicks pressed the start button. What do you know?! It starts right up! WHAT IS GOING ON?!?!

The bike is not overheating as I kept a close watch on the temperature gauge. I live at 7500 feet above sea level and I know the previous owner had not jetted the bike for altitude (maybe this has something to do with the problem?). I just bought this bike about 2 weeks ago so, as you can imagine, this is pretty disheartening. I have taken the bike out on a few rides since I bought it, very similar in nature to the ride I went on today, and had no problems. Any input is welcome.. Thanks in advance!
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post #2 of 11 Old 09-23-2013, 08:54 PM
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Welcome to your new KLR. It will get straightened out

I've had low power problems with my new to me 2003. Not exactly the same symptoms but maybe you can use the same troubleshooting path. I should mention that I live at 5000' and ride to 12,000.

First thing that comes to mind is that you have low or no fuel in the carb bowl. Check tank venting first. The tank can develop a vacuum if it is not vented. Try opening the cap when u notice the problem. U can also duct tape the cap semi open so toucan ride it around.
If that makes it better u can take apart the cap and clean or remove the vent.

Next look at the petcock. It requires a vacuum supply. Check to make sure the hose is connected to both ends. You should replace the hose with something sturdy like fuel line. Old hoses can collapse when they warm up. Then pull off the vacuum and fuel lines. Put the fuel line in a jar and pull a vacuum on the vacuum line. I recommend a mighty vac but have been known to just suck on them when 200 miles from my tools. Should work like this:

No vacuum-- no fuel flow
Vacuum--lots of fuel flow & holds vacuum. That is it doesn't leak the vacuum away. On your mighty vac the gauge should hold steady. Sucking on it should not create the feeling of a steady stream of gas vapor.

If the petcock passes muster it's probably something else cheap and simple. Check back and let us know how you're doing

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Last edited by UncleWray; 09-23-2013 at 08:56 PM. Reason: Forgot to mention my altitude
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post #3 of 11 Old 09-24-2013, 02:49 PM
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First thing I thought was gas cap not venting. Cause I've been there. And it's easy to diagnose. Take a ride with the cap open and see if you have any problems.

A can of seafoam in the tank never hurt anything either.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #4 of 11 Old 09-24-2013, 06:53 PM Thread Starter
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Quote:
Originally Posted by UncleWray View Post
Welcome to your new KLR. It will get straightened out

I've had low power problems with my new to me 2003. Not exactly the same symptoms but maybe you can use the same troubleshooting path. I should mention that I live at 5000' and ride to 12,000.

First thing that comes to mind is that you have low or no fuel in the carb bowl. Check tank venting first. The tank can develop a vacuum if it is not vented. Try opening the cap when u notice the problem. U can also duct tape the cap semi open so toucan ride it around.
If that makes it better u can take apart the cap and clean or remove the vent.

Next look at the petcock. It requires a vacuum supply. Check to make sure the hose is connected to both ends. You should replace the hose with something sturdy like fuel line. Old hoses can collapse when they warm up. Then pull off the vacuum and fuel lines. Put the fuel line in a jar and pull a vacuum on the vacuum line. I recommend a mighty vac but have been known to just suck on them when 200 miles from my tools. Should work like this:

No vacuum-- no fuel flow
Vacuum--lots of fuel flow & holds vacuum. That is it doesn't leak the vacuum away. On your mighty vac the gauge should hold steady. Sucking on it should not create the feeling of a steady stream of gas vapor.

If the petcock passes muster it's probably something else cheap and simple. Check back and let us know how you're doing
Thank you so much for your response! I pulled the fuel and vacuum lines and put a vacuum on the vacuum line and NOTHING. No fuel came out of the fuel line! So what exactly should I do now?
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post #5 of 11 Old 09-24-2013, 06:54 PM Thread Starter
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Originally Posted by Lockjaw View Post
First thing I thought was gas cap not venting. Cause I've been there. And it's easy to diagnose. Take a ride with the cap open and see if you have any problems.

A can of seafoam in the tank never hurt anything either.
I will definitely try the seafoam!! thanks for your response!
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post #6 of 11 Old 09-24-2013, 08:26 PM
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Sure thing. What you describe sounds an awful lot like it's not venting right, though. Try that first. It's free.

But yeah, Seafoam is amazing stuff.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #7 of 11 Old 09-24-2013, 10:10 PM
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Originally Posted by riderj View Post
Thank you so much for your response! I pulled the fuel and vacuum lines and put a vacuum on the vacuum line and NOTHING. No fuel came out of the fuel line! So what exactly should I do now?
You should have flow when the fuel valve is open and a vacuum is applied to the vacuum hose. If not you should check the condition of the diaphragm and the fuel side of the petcock. You will need to remove the fuel prior to doing this or you could remove the tank and position the petcock high enough so fuel will not leak.

It would seem strange that you are moving along fine then the petcock would fail unless it gets clogged or a vacuum line leaks. There are fine mesh filter screens attached to the main and reserve tubes supplying the petcock.

Please keep us updated.
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post #8 of 11 Old 09-24-2013, 10:22 PM
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UncleWray and Dualie are giving you the low down skinny. If you properly located the vacuum line and you applied suction and no fuel out of line I would definitely check the petcock, possibly perform Hurricane mod or a raptor 660 petcock to make it vacuum free..... One less thing to malfunction and leave you stranded somewhere....
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post #9 of 11 Old 09-24-2013, 10:34 PM
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Originally Posted by SkiBumBrian View Post
UncleWray and Dualie are giving you the low down skinny. If you properly located the vacuum line and you applied suction and no fuel out of line I would definitely check the petcock, possibly perform Hurricane mod or a raptor 660 petcock to make it vacuum free..... One less thing to malfunction and leave you stranded somewhere....
Eagle Mike sells a Yamaha manual valve that fits perfectly ( no vacuum connection ) for not a lot of money. He even included a block off for the carb fitting that saved me a trip to autozone. Works great.

UncleWray's Motorcycle Painting & Upholstery

Our Motto: "If it looks real bad from a mile away, you know you came to UncleWray"

Our Guar-ron-tee: "If it doesn't look bad from a mile away, we'll drive you closer till it does!"
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post #10 of 11 Old 09-25-2013, 12:06 AM
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What EM is selling IS a Raptor 660 petcock. Order one from him or just head down to the Yamaha dealer, probably have them in stock, they are very popular.
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