1991 KLR650 Idle Issue - 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 3 Old 11-21-2013, 01:38 PM Thread Starter
Join Date: Nov 2013
Posts: 2
1991 KLR650 Idle Issue

Hey guys Im trying to track an idle issue down on my new to me 1991 KLR650. (14k Miles)I am getting a stumble every 5-10 seconds then it resumes normal idle. It always has 5-10 seconds good idle then a slight stumble then good idling again repeating. I went through the carb pretty darn good and when I replaced the main slide diaphragm it significantly made the issue better, before the stumble would cause the bike to stall. The bike runs great other than this funky idle, has lots of power gets 50-52mpg no odd surges.

Let me give you a list of known mods to the bike so we can clear things up.

IMS 6.6 Tank with Yamaha Raptor Petcock
Eagle Mike Doo-hickey with tortion spring - adjusted
Lexx Exhaust
Uni Filter
Dyno Jet Kit (Off the top of my head it has a 140 main cant remember the pilot jet.
EZ Access mixture screw - not sure of name brand has a small roll pin through it.
Brass local choke plunger
15/43 Sprocket setup with an X-ring chain - not that that matters other than mpg.

Checked Tank Vent Line and its clear.

If anyone has anything for me to check into I would be greatful!

One thing I did notice while poking around I believe the previous owner had the coil off. He did have the valves adjusted within the last 2k miles. So maybe that's when the coil was off anyway the plug wire was coming off the coil pointing tward the engine. I believe the coil output should be away from the engine to take up coil wire slack correct? I may change this around tonight. Anyway I put a piece of radiator hose around the wire to prevent any rubbing.

Last edited by automated11; 11-21-2013 at 01:53 PM.
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post #2 of 3 Old 11-21-2013, 02:10 PM Thread Starter
Join Date: Nov 2013
Posts: 2
I found the brass choke on ebay that the previous owner installed and it looks like very good quality. Hope it isn't causing my idling issue, I cant post links yet but I can pm you the link if it is of concern.
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post #3 of 3 Old 11-21-2013, 05:06 PM
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Join Date: Jan 2011
Posts: 4,706
At idle, only the pilot circuit should be active; assume you cleaned that out well, and that you have adjusted the pilot screw properly.

Air leak from the intake plumbing?

I'd add, "Carburetor diaphragm properly sealed," except--I don't think the diaphragm plays a role at idle.

Not likely the "choke" (starting enricher). When closed, no fuel nor air enters the venturi from this source, except--can't certify the aftermarket "choke" on your bike. The plunger must fit properly, exactly like the OEM part, to insure correct operation.

Wish, I could be more helpful; I'd start with the fuel screw adjustment, once I was convinced the aftermarket choke was o.k. (e.g., plunger profile and excursion range correct, cable attachment cap intact).

Last edited by Damocles; 11-21-2013 at 05:11 PM.
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