Please help! - 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 57 Old 06-26-2014, 01:26 PM Thread Starter
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Please help!

Hi all!
New user here. Just bought a klr last week. It's an '01 with 40k miles. Ran great. I took it home and decided to change the fluids just to start fresh. So... I used that heavy diesel oil that many here have raved about. But I know I added too much because I filled the sight glass while the bike was on the center stand. Anyway... Bike ran excellent so I didn't bother to drain any oil out. I rode until I needed gas without a single blip. I filled the tank yesterday after work all the way to the neck, rode the two miles home and parked her. Left the petcock on last night. This morning I walk out to the bike and notice a puddle beneath. I thought it was just fuel from overfilling and leaving the petcock on. So I try to crank it over and the starter just clicks. Won't crank at all. Battery is newish and that's not the issue. What the heck did I do!? And more importantly how do I remedy it!?!

Thanks in advance to you klr gu-ru's
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post #2 of 57 Old 06-26-2014, 02:19 PM
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Conceivably, you have hydrostatic lock . . . if you have a MANUAL (vs. a vacuum-actuated) petcock, and left the lever in the ON position overnight, and if your carburetor float valve isn't sealing fully, fuel could flow on the floor, as you mention, and maybe into the engine. If the fuel flowed into the engine, past the intake valves, the liquid could accumulate in the cylinder. Since liquid is virtually incompressible, you could experience hydrostatic lock.

Cure: remove spark plug and purge fuel from cylinder; drain and replace engine oil if contaminated.

On the othe rhand . . . if all you get is a "click" when you push the starter button, you may have only a weak battery, or bad electrical connection.

Hoping it's case # 2!

(I'd jump it with a known hot battery, before I cried, "Hydrostatic locke!" in earnest. If you have a stock, vacuum-actuated petcock, most unlikely you have hydrostatic lock.)
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post #3 of 57 Old 06-26-2014, 02:26 PM Thread Starter
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99.9% sure it's not a battery issue.
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post #4 of 57 Old 06-26-2014, 03:00 PM
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Quote:
Originally Posted by Awsii View Post
Hi all!
New user here. Just bought a klr last week. It's an '01 with 40k miles. Ran great. I took it home and decided to change the fluids just to start fresh. So... I used that heavy diesel oil that many here have raved about. But I know I added too much because I filled the sight glass while the bike was on the center stand. Anyway... Bike ran excellent so I didn't bother to drain any oil out. I rode until I needed gas without a single blip. I filled the tank yesterday after work all the way to the neck, rode the two miles home and parked her. Left the petcock on last night. This morning I walk out to the bike and notice a puddle beneath. I thought it was just fuel from overfilling and leaving the petcock on. So I try to crank it over and the starter just clicks. Won't crank at all. Battery is newish and that's not the issue. What the heck did I do!? And more importantly how do I remedy it!?!

Thanks in advance to you klr gu-ru's

Yea it's hydro locked, don't crank the starter you can bend the rod!

Take the tank off to get to the spark plug. Take the plug out and place a good size rag over the hole. Now crank the starter, gas will shoot out of the spark plug hole hence the rag!

More than likely the flooded cylinder flooded the crankcase, the gas seeps past the rings. So you will need to change the oil also.

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 57 Old 06-26-2014, 03:14 PM Thread Starter
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Thank you...
I hit the starter three times. Momentarily.. Didn't hold it down. Each time all I got was a click. Think I hurt anything?
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post #6 of 57 Old 06-26-2014, 04:05 PM
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Quote:
Originally Posted by Awsii View Post
Thank you...
I hit the starter three times. Momentarily.. Didn't hold it down. Each time all I got was a click. Think I hurt anything?

Probably not. Chances are the piston is at the bottom of the stroke or on it's way up so the starter didn't have enough torque to move it.

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

Last edited by Spec; 06-26-2014 at 04:10 PM.
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post #7 of 57 Old 06-26-2014, 05:11 PM
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great topic - keep the info comming
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post #8 of 57 Old 06-26-2014, 05:20 PM
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Awsii,
In case the cylinder is flooded, you better Disconnect the small primary wires from the Ignition Coil, Before cranking the engine over!
Or you may have a Flaming KLR.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #9 of 57 Old 06-26-2014, 05:56 PM Thread Starter
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Thank you for that advice.
Honest to god I thought I was going to do jut that this morning as the third time I hit the ignition button a small spark jumped from the terminal and hit the ground near the puddle of gas. I think the spark was due to the fact that the starter motor was trying to spin up to no avail. Anyway... Very lucky I didn't bbq the new-to-me toy.
I will head your advice and make the bike safe before proceeding.

I'll keep the progress posted. I can't do anything tonight due to prior engagements. Even though I'd much rather be turning wrenches than eating dinner with the inlaws.

Here is my plan I attack. Please interject if I forgot anything or got anything out of sequence.

Unplug + coil lead
Remove carb bowl and drain fuel
Remove all oil/fuel from air box
Drain oil
Remove spark plug
Force out raw fuel via starter
Reassemble
Add PROPER amount of oil
Turn petcock on
Start bike and let run several minutes
Enjoy bike again.

One concern I have... Will the fuel in the lower crank case have washed the oil off the cylinder walls/crank/ etc? And does that pose a risk?

Thank you all again.
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post #10 of 57 Old 06-26-2014, 07:22 PM
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Quote:
Will the fuel in the lower crank case have washed the oil off the cylinder walls/crank/ etc? And does that pose a risk?
The residual gasoline in the cylinder and sump will be of no consequence, with fresh, uncontaminated oil in the crankcase, IMHO.

Do you have a manual petcock?

If not, hydrostatic lock becomes less likely.

My colleagues think hydrostatic lock is the problem. Could be! The symptom mentioned, "Just a 'click,'" is the same as for a low battery.

I doubt the starter alone can bend a rod; with a multi-cylinder engine, a rod can be bent from an unaffected cylinder firing with a victim cylinder filled with fuel. Don't think a hydro-locked single-cylinder engine will fire, reducing mechanical damage risk and fire danger. When s hydro-locked single cylinder is cleared of fluid, and the engine DOES fire, however, a hazard exists in the volatile fuel that may have migrated throughout the intake manifold and into the crankcase. Defeating the spark remains sound safety practice, regardless.
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