Need suggestions/ insight - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 1Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 23 Old 11-25-2015, 07:02 PM Thread Starter
Neutral
 
Join Date: Nov 2015
Posts: 2
Need suggestions/ insight

Hi All,
Just got myself a new '99 KLR (A13) with 3k miles and have already found a few concerns, hoping you guys can suggest some tests or areas to investigate so I can avoid taking it to a professional.

- engine bogs when i crack the throttle. this happens in neutral and while shifting gears (either stalls or rebounds depending on how i flutter the throttle)
-front brake sticks at the handle (will bleed tomorrow)
- No tail light (running) but front and rear brake switches function properly
-No head light (hi nor low) checked switch and cleaned contacts, will check the fuse tomorrow. After cleaning the headlight switch, i reassembled switch and now my turn signals won't blink when fired, they stay illuminated.
gullymonster is offline  
Sponsored Links
Advertisement
 
post #2 of 23 Old 11-25-2015, 07:17 PM
2nd Gear
 
frostbitevinnie's Avatar
 
Join Date: Oct 2015
Location: St. Cloud, MN
Posts: 259
How does a person average 187.5 miles per year for 16 years? Amazing. Looks like you have a bike that just needs a little tlc. Clean the carb, probably replace stock jets. Debug the electrical and ride. I suppose the tires are original as well. Might want to change them for new.

Video of carb overhaul

http://www.klrforum.com/how-tos-tech...-overhaul.html

'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
frostbitevinnie is offline  
post #3 of 23 Old 11-25-2015, 08:14 PM
4th Gear
 
CheapBassTurd's Avatar
 
Join Date: May 2009
Location: Indiana/ Michigan line at the Lake
Posts: 1,586
What Vinnie said.

Hibernation sickness.

A wire likely got pinched upon reassembly.

If the ride was stored outdoors especially the whole thing needs
gone over for dryrotted vac-lines, tire condition, corroded
switches (NP, scuff w/ wire brush), and lube everything.
Throttle n' clutch cables, choke cable is under the tank and probably fine,
see if the balancer chain tensioner upgrade has been done, just a
general checkup and physical. Don't see much reason it won't wail quite soon.

This is my son, with whom I am well pleased." ----God
CheapBassTurd is offline  
 
post #4 of 23 Old 11-26-2015, 09:58 AM
5th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,827
...As I told you "elsewhere";

- bogging is likely the carb; take it off and clean it thoroughly including all jets and passages. Careful of the plastic enricher nut and the carb diaphragm.

- front brake sticking at the lever is probably the lever/mounting bolt. Remove, clean, grease.

- headlight is probably the fuse under the seat; use a 15amp this time around.

....I'll let others chime in about the other electrical issues; not my forte.

As far as the mileage goes, I just purchased a 2000 model this spring with 578 miles on it. At first is wouldn't run off idle but I got lucky and it cleared itself out. I still went through the carb when I installed the KLX kit though.
The only other items that demanded attention were the battery and tires (which were still like new but dry rotted). A new AntiGravity LiFePo battery and a D606 rear and MT21 front and it worked like a champ.

Cheers,
Dave

justjeff likes this.

Last edited by klr4evr; 11-26-2015 at 12:58 PM. Reason: Image moved.
DPelletier is online now  
post #5 of 23 Old 11-26-2015, 10:21 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,711
No tail light; could be on the headlight fused circuit; could be the tail light/brake light bulb (has two filaments).

Carb could have diaphragm air leak; hole/tear in diaphragm fabric, improper seating around periphery.

Wiring diagram on 'Net; Google, "KLR650 Wiring Diagram," look for the Generation 1 edition. A multimeter is your friend.

+ 1 on the 15-amp replacement headlight fuse.
Damocles is offline  
post #6 of 23 Old 11-26-2015, 07:03 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,260
Quote:
Originally Posted by Damocles View Post
..................
+ 1 on the 15-amp replacement headlight fuse.
I am curious why you would use a fuse 50% larger than the OEM spec size.
GoMotor is offline  
post #7 of 23 Old 11-26-2015, 07:36 PM
5th Gear
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,206
On the Gen1 bikes the headlight switch can activate BOTH high and low beam circuits at the same time as you move the switch from low to high or low to high. The extra power draw when both beams are on can pop the factory fuse even though there is no short or fault. A higher amp fuse prevents this inadvertent fuse failure. You don't want to go with too big of fuse just in case there is a REAL short in the wiring though!
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
justjeff is offline  
post #8 of 23 Old 11-26-2015, 08:42 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,711
+ 1!

Don't think going from 10-amp to 15-amp headlight fuse is especially radical. Kawasaki upgraded the fan fuses from 10-amp to 15-amp on Generation 2s, so--upgraded fuses are not without precedent.

On the other hand, thousands of miles of service with an OEM fuse are not impossible or necessarily, even unlikely. Regardless, a 15-amp fuse or two as spares might come in handy some day.
Damocles is offline  
post #9 of 23 Old 11-26-2015, 08:43 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,260
Quote:
Originally Posted by justjeff View Post
On the Gen1 bikes the headlight switch can activate BOTH high and low beam circuits at the same time as you move the switch from low to high or low to high. The extra power draw when both beams are on can pop the factory fuse even though there is no short or fault. A higher amp fuse prevents this inadvertent fuse failure. You don't want to go with too big of fuse just in case there is a REAL short in the wiring though!
Regards....justjeff
I see. I thought fuse sizes were selected to protect the wire and a larger fuse would allow an over load to take out the wire instead of the fuse.
GoMotor is offline  
post #10 of 23 Old 11-26-2015, 09:08 PM
5th Gear
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,206
Technically that is true, the fuse can be sized for the maximum continuous load capability of the wire but often the fuse is sized to be just above the load of the accessory instead. The wire may be oversize and capable of a higher load due to other reasons such as mechanical durability or economics. KTM has been criticized for using too light of wire in their harnesses and having wiring issues related to vibration and wear.
JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
justjeff is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Insight Two Dogz The Off Topic Lounge 0 09-26-2012 12:52 PM
Looking for some suggestions Fire44 Southeast Riders 6 05-25-2012 11:15 AM
Suggestions please. Aron31 2008+ KLR650 Wrenching & Mod Questions 4 05-11-2012 08:20 PM
Vacation Suggestions Paper The Off Topic Lounge 9 07-14-2011 09:30 PM
A bit of insight to long distance rally riding Paper The Off Topic Lounge 0 05-27-2010 10:09 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome