Won't idle, floods and dies. - 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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Old 06-25-2008, 07:33 PM Thread Starter
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Join Date: Jun 2008
Location: Richmond, Kentucky
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Won't idle, floods and dies.

2002 KLR 650 : Pulled up to a stop sign a few feet from home (luckily) and it just died, pushed it on home and this is what has transpired. It would start with the throttle wide open and would stay running at about 3K if you feathered the throttle but if you let it idle down it just died. I've had the bike about a month and had just filled up on my second tank of gas. I rode about 25 miles that morning and had ridden about 75 miles the day before. It runs better if you choke it about half way but then I notice small puddles of gas on the ground that seem to be coming from the airbox.

I drained the carb float bowl into a glass jar and saw minimal fine sediment and no signs of water in the gas. Removed the seat and tank to check battery connections and wiring under the tank between the battery and the forks hoping to find some kind of electrical short. On what I think to be very good advice I proceeded to drill the plug from the idle/mixture jet hole on the bottom of the carb, dropped the float bowl where there was a good bit of sediment, backed out the idle/mix jet and gave everything a good cleaning with carb cleaner. I was very hesitant to try this because a mechanic I'm not but was feeling very good about the whole thing at this point.

So as I'm screwing the idle/mix jet back in I notice some resistance so I back it out again and peer up in there with a flash light and a magnifying glass (old eyes) and I see what appears to be a little washer and part of an O-ring. Part of an O-ring mind you. When I backed the screw out the first time all that came out was the screw (jet??). I fished around up in there and also managed to get a little spring out. Well there was apparently more that I hadn't seen and it seems when I put the jet and spring back in the resistance I encountered was the jet pushing part of that O-ring up into the hole where the jet was supposed to go. I finally got the little washer out and part of the O-ring. I've tried everything in my toolbox but can't find anything small enough too get up in that little hole to retreive the last bit of the O-ring. From what I did get out there's probable alittle less than half of it still up in there.

Am I going to have to pull the carb off the bike and completely disassemble it to clean up this mess? Any and all suggestions will be most appreciated!!!

Unlucky in Kentucky
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Old 06-25-2008, 07:44 PM
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Location: Corpus Christi, TX
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Wow. Maybe a noose of fine wire or light (2/4lb) monofilament fishing line. Maybe shopvac. Grasping at straws (or O rings) here.
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Old 06-25-2008, 08:41 PM
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Join Date: May 2007
Location: Richmond, Ky
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Here is a link with the picture of the parts, there is a spring, washer and then the o-ring that the needle fits thru. Give me a call tomorrow and I will be more than happy to come over and help in any way I can. I have some mechanics picks that might work on getting the rest of the o-ring out. Compressed air might work well too.

http://www.aldra.ch/EZ_Just_installanleitung.pdf

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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Old 06-25-2008, 10:55 PM
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Location: Red Bluff Ca.
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Might want to look at the fuel tap and the supply line to the carb . The rubber gasket inside the tap/supply line deterioates, the pieces get stuck holding the float open, causing it to flood. The (gas on the ground)coming from the overflow.
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Old 06-27-2008, 08:26 PM Thread Starter
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Join Date: Jun 2008
Location: Richmond, Kentucky
Posts: 3
Just got the O-ring piece out! Thanks to Big Iron for the wire suggestion, took awhile but worked great. I've been working a bunch of hours and haven't been able to get to the dealer in our town to order a new one.
The folks on this forum are great! DXKLR just happens to be in the same town, doesn't know me from Adam, went in and ordered the part for me and has offered to help get it back together. If you watch the news every night you begin to think this old world is going off the deep end, then somebody turns up and restores your attitude about your fellow man. Thanks to all!!!
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Old 06-27-2008, 08:36 PM
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Location: Richmond, Ky
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Awww shucks... 'kicks dirt with toe' .... Now I gotta be mean so everyone will think I am normal..........LMAOOOO KLR guys take care of KLR guys. Rule number one. That is great that you got the pieces out, will make fixing it faster now.

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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Old 06-28-2008, 07:50 AM
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Mr. Karma says "You get back what you give" even when you give because it's the right thing to do.
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