HELP! Died on Highway. - 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 15 Old 05-05-2008, 10:42 PM Thread Starter
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Location: Nanaimo, BC, CANADA
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HELP! Died on Highway.

Well today was my first ride. It didn't go well in the end. 2003 with 8000KM. Only mod is a muffler (jardine). Ran beautiful for first 50KM today, low speeds, high speeds, multiple stops and starts. then i was heading home and merging onto the highway .....then it started to sputter, just like it was out of fuel. So, I figure it was maybe low on fuel or ther was some water in the fuel. Pulled over, lots of fuel in the tank. When i put the choke on it will hold 3-4000rpm. With it off it idles great at 800-1000 rpm. starts very easily. but if i give it any throttle (choke on or off), it sputters and dies. Rode 2 km with the choke on and shifting at 3000rpm. Cables on carb are all free an moving normally.Tried a fresh tank of gas, no help. Called the wife to bring the truck. .... Any guesses? seems pretty weird. something mechanical? what are the symptoms of the doodad failure? Thanks in advance.
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post #2 of 15 Old 05-06-2008, 06:47 AM
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Have heard of this happening a couple of times. It sounds like you are one of those getting a vaccum inside your tank, not allowing the fuel to flow. There is a very easy simple fix for this. Remove the vent seals in the gas tank lid. Secondly, you might have a crack in the vaccum line that runs to your fuel tank petcock. If there is not enough vaccum, your petcock won't open fully allowing fuel to flow to the motor. There is a fix for that also.
Here are the links for each fix:

Vent Seal Mod:
http://klrworld.com/forums/index.php...gas+vent+seals

More than likely this next mod will fix your problem.
Petcock mod:
http://klrworld.com/forums/index.php?topic=7255.0

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 15 Old 05-06-2008, 03:35 PM Thread Starter
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thanks. I vented the tank, which didn't help. I'll try the petcock mod, sounds a little more like it. I'll update when fixed or frustrated. thanks.
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post #4 of 15 Old 05-06-2008, 04:02 PM
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The only other thing I could think of but doubt, would be the diaphramg on your needle slide inside the carb. My buddies had a 1/4 in. cut in it, more than likely my doing while putting in new needle, and it would idle fine, but ran like crap on the road, because the vacuum couldn't raise the needle to add more fuel above the 3000 RPM range.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 15 Old 05-07-2008, 02:18 PM
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My two cents worth. It is likely a carb thing.
If it runs with the choke on, and will idle until you try to pick up any throttle:
I suspect water in the float bowl or trash plugging the main jet.
Try draining the float bowl, catch the fluid and inspect for debris or water.
Good luck.

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post #6 of 15 Old 05-08-2008, 11:11 PM Thread Starter
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drained the float (normal) and inspected the jets (not clogged). I was tempted to put in the jet kit i have, but then thought ....maybe i should get it running right first.
Also i took the tubes off the tank but couldnt get any flow. Shouldn't i get gas coming out when the petcock is turned to on or reserve? me thinks so. I'm think it must be the diaprhagm in the petcock.
more later
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post #7 of 15 Old 05-09-2008, 03:16 PM
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You won't get fuel unless the engine is running. That second link I sent you was how to by pass that problem. The petcock has to have engine vacuum in order to supply fuel to the carb. This mod will allow a better fuel pressure inside the tank and you won't have failure of fuel flow if the petcock goes bad. You should see TWO black hoses going to the petcock. The largest on the outter side is your fuel line, the smaller one up and behind that is your vacuum line. You might check to make sure it is in place and that the line does not have any cracks or holes in it. If you have a hand operated vacuum pump you can use it to trouble shoot the petcock and hose.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #8 of 15 Old 05-09-2008, 07:44 PM Thread Starter
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running again! took the petcock off and shortened the tube. reinstalled and she is up and running again. need to replace the diaphragm with a sold gasket at a later time.
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post #9 of 15 Old 05-09-2008, 08:19 PM
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I have been waiting till I am low on fuel to shorten the supply tube in mine too.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote
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post #10 of 15 Old 05-10-2008, 01:02 AM Thread Starter
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thanks for your help. Hurricane has sent me one (what a great guy, eh?). My advice to anyone who hasn't done the mod, would be to do it before you get stranded like me. no prior warning or surges detected - just quit and had to call for rescue. cheers.
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