neglected KLR650 loud startup, oil smoke - 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 9 Old 04-17-2016, 12:25 PM Thread Starter
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neglected KLR650 loud startup, oil smoke

OK, I know I'm a jerk, but I haven't started my 97 KLR650 in oh...3 years.

I started doing some maint to get her back into shape - drained the tank of it's yellow varnish gasoline, removed the carb and cleaned it thoroughly. Charged the battery and checked the oil - had to add some as it didn't register on the sight glass. Oil is now barely registering when on side stand and top of sight glass when the bike is level.

When trying to start the bike, it is LOUD. I've tried giving it some revs to work out whatever residual bad gas might be in the system, but it simply won't idle. There's a lot of blue smoke coming out of the exhaust (which I assume is oil). Not sure where to get started on this beast now. I've included a video, which doesn't really capture the loud nature of the bike...it's sort of scary loud which I don't remember being the simple sewing machine sound I remember.


http://youtube.com/watch?v=Or1qIoUeOPg
.

Last edited by klr4evr; 04-17-2016 at 04:29 PM. Reason: Embed video.
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post #2 of 9 Old 04-17-2016, 03:17 PM
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Some may disagree with me... but.....
I personally would put some Marvel Mystery Oil or ATF (3-4 table spoons) in the spark-plug hole and let it sit a day or 2, then turn engine over before replacing plug to make sure you don't hydro-lock.

Sound like stuck rings...

Gordon

"Things are made out of Stuff"
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"Singularity is a scientific term for - We Just Don't Know"
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(2011 KLR)

Last edited by gruet782; 04-17-2016 at 03:25 PM.
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post #3 of 9 Old 04-17-2016, 08:17 PM
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darien99,
Sounds like the typical KLR650 in a small shed to my ears.

As to the idle, I'm just guessing that you may Not have removed the Pilot Jet from it's 'pocket' up inside the tower. If the jet itself or any of the pilot holes at the Bottom Edge of the throttle butterfly plate or the pilot mixture screw outlet hole are still restricted or plugged, it won't idle and it won't respond properly to throttle input.

Clean the carb again, this time more thoroughly and with more attention to the finer points.
Good reading and video over here,
http://www.klrforum.com/how-tos-tech...ing-cvk40.html

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #4 of 9 Old 04-18-2016, 01:14 AM
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If you are showing oil in the sight glass while on the side stand, it is very over full. The oil should be just below the top of the sight glass when the bike is dead level.

Drain the excess oil and see how it runs.
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post #5 of 9 Old 04-18-2016, 03:32 PM
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Normk,
He did say the oil was at the "top of sight glass when the bike is level".
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post #6 of 9 Old 04-18-2016, 04:06 PM
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Apparently my attention span is poor. :-)
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post #7 of 9 Old 04-19-2016, 08:19 AM
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Quote:
Originally Posted by darien99 View Post
I've included a video, which doesn't really capture the loud nature of the bike...it's sort of scary loud which I don't remember being the simple sewing machine sound I remember.
As pdwestman also commented, it sounds ok to me too.

What would help is "volume" a point of reference like if you spoke to the camera then started the bike we could adjust our volume to your voice then hear the difference between your voice adjusted to a normal volume and the bike's noise level.
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post #8 of 9 Old 04-19-2016, 09:08 PM
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Do you mean its loud exhaust wise, or loud metallic rattle loud? I'd say check the balancer chain tension (just incase the doohickeys loose or broken), clean the carb again like pdwestman says, and give it a run. It may just be oil soaked carbon on the piston and a run will dry it out.
I'd drain the oil and put new in before you ride it.
Hope it helps
Ian
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post #9 of 9 Old 04-19-2016, 09:14 PM
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Sound files are difficult, but I'd hazard there is an idle circuit problem such as plugged pilot or a vacuum leak + an exhaust leak.

A loose and leaking exhaust can sound like a mechanical problem, especially if the flange is at an angle and hitting the head.
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