KLR Newb carb question - 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 14 Old 09-23-2008, 05:05 AM Thread Starter
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KLR Newb carb question

This is my first post to this forum so take it easy on me...I've been hanging out over at thumper talk, but since I just pick up my first KLR, I've been seaching for the perfect Dual Sport for years now and have come to the inevitable conclusion that it doesn't exsist so I figure between my plated XR400 and my new (to me) KLR, I've got the full DS spectrum covered! So - the question:
I picked up an 05 KLR650 thats been in storage for a year or so. Low miles.
Idles with the choke on, dies with choke off. Crack the throttle and it dies. Twist the throttle full open quickly and it'll run at high revs, backfiring occasionally. Choke has to be left on or it'll die at idle. Pulled the bowl. Main jet is clear. pilot clear. Rode the bike in hopes of clearing it out but no luck. backfires and runs only at idle or about 2/3 or more throttle. Something else I noticed when I pulled the fuel hose off the carb to drain the tank...The tank wont drain no matter which position the petcock is in I think I remember reading something about this on KLRs ?? Anyway, theres fuel in the bowl so it s getting fuel. I'm about to pull the carb and start looking and cleaning but I could use some arrows pointing to potential causes
Thanks!!!!!!!!!
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post #2 of 14 Old 09-23-2008, 07:48 AM
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Welcome aboard Trail70...

If you are positve the carb is 'completely' clean and it still has the 'won't idle' issue, you may need to check the idle diaphram, it could be dry rotted.

The item number is underlined in red and red line pointing to the diaphram.

http://img109.mytextgraphics.com/pho...4byl9jyz1.jpeg

As for the fuel draining, you need to apply vacuum to the petcock in order for the valve to open to drain fuel. That will be the small vacuum line behind the fuel line on the back side of the petcock.

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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 14 Old 09-23-2008, 12:17 PM
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I'd run a half can of Seafoam in a gallon of gas for a few minutes and then let it soak overnight then run the rest of the gas thru it, on the road varying speeds if possible. I'm betting you have a passage or seat varnished up.

If that doesn't help it, then dissamble, soak in solvent and blow out with compressed air. You'll be able to pick up on any deteriorated orings or diaphraghms when you take it down.

I'd suggest not doing any mods, "22cent" or otherwise, until it runs correctly stock.

I usually use Berrymans but Seafoam seems a little "stronger" and might be more better for year old crud.
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post #4 of 14 Old 09-23-2008, 04:09 PM Thread Starter
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Unfortunately I'm in Germany and Ill likely never find seafoam or berrymans. You cant even buy weed killer without a federal license and 4 years of training. I'm gonna go back into the carb and reinspect and clean. I'll just chalk it up to "gettin to know my KLR"

Thanks for the advice
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post #5 of 14 Old 09-23-2008, 04:21 PM
 
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definatly sounds like a idle circuit blockage,that would be one of the circuits that the pilot jet feeds and is controlled by the mixture screw, i came across this recently on a drz125 i got for my boys, the hole in the pilot jet is TINY as is the one on the klr , so are the circuits it feeds, so lots of carb cleaner and compressed air works well, i bought a new pilot jet after unsuccessfully trying to clear it, and i believe the diaphram that DXKLR was pointing out is an enrichment valve to prevent backfire on decel
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post #6 of 14 Old 09-23-2008, 04:24 PM
 
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here is a link for the cutaway of the carb and a description of the circuits
http://www.johnsmotorcycleparts.com/...tor-images.htm
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post #7 of 14 Old 09-23-2008, 04:27 PM
 
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the three small vertical passages near #1 are essential for idle and performance on the lower 1/2 of the rpm range i know this is a Harley carb but is the same as a klr except the Harley has an accelerator pump
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post #8 of 14 Old 09-23-2008, 04:28 PM
 
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this site also has nice metal fittings to replace the cheesy ones on the klr
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post #9 of 14 Old 09-23-2008, 05:11 PM
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Acetone will serve the same function as Seafoam or Berrymans but is much harsher. I'd probably use about 4 ounces to a gallon. Run it a bit, let sit for a few hours, then run until most of the gas is gone. I'd then purge all the gas mixed with acetone and replace with new gas and run for awhile.

Might be best to disassemble and soak in solvent and go from there rather than try the easy way.

Trail70, if you're in the military, your motor pool guys should have something to fix you up.

edit - I've used acetone like that in a couple of old cars with no problem, but I'm a little shakey suggesting it. I'd probably also change oil after the treatment.

Last edited by BIGIRON; 09-23-2008 at 06:40 PM.
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post #10 of 14 Old 09-24-2008, 04:35 PM Thread Starter
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BIGIRON
Pulled the pilot and cleaned it today with decent results. Now the bike revs smooth from idle to power, which is a huge improvement, but still needs half choke to keep from dying at idle. I actually found berrymans carb cleaner on the shelf at the base gas station and put about 8 oz in a nearly full tank. We've got plenty of ketone in the hanger (a relative to aceton I think)but Im gonna see if the gas treatment helps and maybe another go at the carb with cleaner + air. This forum seems to have a lot of knowledgable people hanging out here. Thanks
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