Won't start - 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 07-05-2016, 12:42 PM Thread Starter
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Join Date: Jul 2016
Location: Southern California
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Won't start

Hello all,

I've got an 2002 CA Edition, 15k miles, and I cannot get her to start after a carb rebuild

2 weeks ago I rebuilt the carb, 100%. Complete strip down, soak and rebuild with all brand new parts. (Only things not replaced, floats and brass tube the jet is screwed into.) I also triple checked the needle jet is installed.

Set the new mixture screw to 1 3/4 turns, and reinstalled. She fired right up, idled perfect (with a slight adjustment on the idle knob, she was idling around 2k, backed her down to 1500)

Went for a 20 min ride and no issues, in fact she pulled better than she ever had.

Came home, parked her. Went to start her up an hour later, and just looking at the starting switch she would fire up.

Now here is the issue:

Two weeks later went to hop on her for a ride and she wouldn't start. She turns over, cranks, and while playing with the choke, (I'm in southern Cali and it's hot out here) I can get her to sputter with a little whispy puff-pop. But that's it.

Mods: none, she's stock

I'm up for any suggestions (that's why I'm posting)

Thanks,

Vaportrail

History: saved her from the salvage yard, buddy had her in storage for the past 4 years. He was doing 70 on the freeway when the chain broke. He didn't go down, but the chain wrapped around the rear and whipped through the entire rear end, splitting the air box and battery in half, literally. Not to mention chewing the chain guard and beating the living crap out of the swing arm, and eating the rear fender.

Stripped her down and rebuilt her from the ground up.
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post #2 of 15 Old 07-05-2016, 10:24 PM
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I would consider shutting of the petcock, draining the float bowl and squirting a shot of starting fluid in the air box. If it fires up on the starting fluid, think about going back into the carb.
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post #3 of 15 Old 07-07-2016, 12:10 PM
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Basics....Make sure the carb is getting fuel. Drain the float bowl and make sure it fills back up when turning the engine over. If you are not getting fuel into the carb it could be a malfunctioning fuel petcock. Just because you did work on the carb doesn't say there isn't something else malfunctioning.
Next check for spark at the spark plug. A bad plug can spark outside the cylinder and NOT spark while installed. Install a different one for testing.
If you have fuel in the carb and spark and have tried the starting fluid idea I would certainly look into the carb again.
JJ
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It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #4 of 15 Old 07-08-2016, 02:11 AM Thread Starter
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Thank you everyone for the responses.

I've been trying to say thanks since the first suggestion only to get caught in a forum "login" loop while trying to reply.

I'll give all these a try tomorrow and let you guys know.

After scouring the forums (again) it actually sparked (pun unintended) a few other ideas. Which I will try out as well.

(1 and 3/4 turns on the mixture screw might be way too lean, hence the wheezy-pop-puff, plus I might have lowered the idle screw so darn low it cut off to much of the fuel/air.) this came to me after reading the old doc on how the CV works, that was stickied but I missed reading.


Thanks again,

Vaportrail
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post #5 of 15 Old 07-08-2016, 07:56 AM
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Contaminated fuel could be the source of the ills.

Draining tank and re-filling with fresh gasoline might do the job; maybe a little "better living through chemistry" additives included.
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post #6 of 15 Old 07-10-2016, 10:26 PM Thread Starter
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Well, I said I would update and here goes....

Everyone was correct!!

First and foremost I yanked the carb and seriously, I've never seen a carb so dirty, contaminated before when it was spit polished 2 weeks ago. My needle had funkies left and right, the needle jet had some nasty caked on stuff to it. It wasn't until I disassembled the de-acceleration pump when I found solids stuck to the inside rubber. Cleaned throughout, again. (And plopped in the .22 cent mod, using 2 3mm washers, rather than the 4, because the 4mm was a bit too wide and touched the plastic thingie. I don't remember what it's called. Oh and backed the mixture screw two 1/4 turns instead of the 1 3/4)

Next, I went looking for the source of the crud.

I disassembled the petcock, found more sediment inside, (side note: noticed my screens are trashed, too). Which led me to draining the tank. Right at the end, bingo, the crud came out. Threw in a little more gas and swished and rinsed until clean.

Installed a see through filter in the gas line just in case.

Poured in some fresh 91 and she fired right up. Ran her up to temp and dialed in the idle. She's back up and runnin'.

Thanks again for the suggestions! Nice job guys.

-Vaportrail

Last edited by Vaportrail; 07-10-2016 at 10:28 PM. Reason: Clarity
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post #7 of 15 Old 07-10-2016, 11:15 PM
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So it wasn't the sparkplug?
JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #8 of 15 Old 07-10-2016, 11:25 PM
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First, THANKS for the update! Too often, we never hear of any results from our "sage" advice!

But . . .

Accelerator pump? Stock KLR650s ain't got no stinkin' accelerator pump!

Some Harley Hog Keihin CV40 carbs, and some Vulcan Keihin CVK40 carbs had accelerator pumps, but . . . never a stock KLR650 CVK40, to my knowledge and belief.

Or . . . do you have an aftermarket carb?

Please share an image.
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post #9 of 15 Old 07-10-2016, 11:41 PM
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Damoclese,
He said "de-acceleration pump" I believe he is talking about the air cut valve assembly on the left side of the carb body.
JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #10 of 15 Old 07-11-2016, 12:15 AM Thread Starter
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Doh, for some reason when brain doesn't function correctly it makes up crap. Justjeff got it right, it's the air cut of value. For some reason my brain went, hey this is used when your decelerating , to not cause popping sooooo de-acceleration pump was created..lol

I blame the gas fumes....

Whoops.

-Vaportrail

Last edited by Vaportrail; 07-11-2016 at 12:16 AM. Reason: Just cause
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