Is it the carb or electrical? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

LinkBack Thread Tools Display Modes
post #1 of 7 Old 02-01-2009, 12:26 AM Thread Starter
Join Date: Feb 2009
Posts: 2
Is it the carb or electrical?

I have used my bike very little over the last few months. Last week it ran fine. Started it today and the motor starts and runs for about 15 seconds, then dies. It will run fairly normal with the choke on - a few misses, but it does not quit on its own. Turn the choke off and it dies within a few seconds. I thought it might be the carb, so I pulled it, disassembled it and cleaned all the parts with carb cleaner. When held up to a light, you could see through all the holes in the jets. The float valve did not look like it was sticking and there was not any debris in the float bowl.
Once the carb was reassembled and installed in the bike nothing changed. Turn the bike on, hold the throttle at 3k rpm and within 10 Ė 20 seconds it dies.
I siphoned out the gas and put fresh gas in, same issue.
Pulled the fuel line from the petcock and started the bike up Ė gas flowed from the petcock at an amazing high rate (1/4 cup in seconds).
A bad plug, short in coil????? Please help if you can.

KGB922 is offline  
Sponsored Links
post #2 of 7 Old 02-01-2009, 01:42 AM
2nd Gear
motorheads5's Avatar
Join Date: Sep 2008
Location: Ketchikan Alaska
Posts: 147
I hate to say it but it sound's like the carb still, if it would not run with the choke I would think otherwise. pull it apart again and remove the jet's and use the pee tube in all passages. carb's can be a pain sometimes. if it was an ignition problem the choke would not have any affect. did you have the choke on when you unhooked the fuel line from the petcock to check fuel flow? if so try it again with the choke off first before you go and take the carb apart again. just for grin's put a new plug in it also. good luck.
I hope this will help you.

Last edited by motorheads5; 02-01-2009 at 02:27 AM.
motorheads5 is offline  
post #3 of 7 Old 02-01-2009, 09:51 AM Thread Starter
Join Date: Feb 2009
Posts: 2
Thanks for the help. As soon as I can I will check it out and get back.
I was so focused on the carb I did not even think about the plug. I remember it was missing a little bit while running with the choke.
I cleaned the air filter last week and took the bike for a short ride, not thinking and starting it before the freshly oiled filter dried. I may have multiple issues here???

Oh the memories,

'02 KLR650
'97 Goldwing
KGB922 is offline  
post #4 of 7 Old 02-02-2009, 12:01 AM
1st Gear
bluestreek's Avatar
Join Date: Jul 2007
Posts: 41
Possibly diaphragm or pilot jet

08 Blue KLR 650
05 Yamaha FJR 1300
86 Honda Fourtrax 250R
87 Suzuki 500 LT
07 Honda Ridgeline

IBA# 25898
bluestreek is offline  
post #5 of 7 Old 02-02-2009, 04:23 PM
Join Date: Feb 2009
Posts: 26
Typical pilot jet problem. It's probably clogged with varnish, and you can still see light through it regardless. Pull the jet and make sure you can actually blow through it. Undo some stranded copper wire and poke it out with one strand. Next time drain the carb and run it dry before putting it up for anything longer than 2 weeks.
ttpete is offline  
post #6 of 7 Old 02-11-2009, 12:45 PM
1st Gear
Join Date: May 2008
Location: Portland Oregon
Posts: 34

Make sure that the vent tube is clear. This is the one that is a fairly transparent yellowish orange color of tube. It is routed down with the rest of the hose cluster and exits around the lower mount of the monoshock. This gets plugged on every bike eventually. I was having the issue when going through water, not a lot of water, but enough that the water was splashing up, plugging the hose for a few seconds, and when it did, the bike leaned out and died. Then the water drips out of the hose, fires right back up, and you are left wonder what electrical thing got wet and killed it. It took me a long time to figure it out. Most bikes accumulate dirt until eventually it is just plugged. Cleaning it works, but re-routing it up high is a permanent fix.
The symptoms you described, are precisely what has happened to a couple of buddies, and when we pulled the hose up to look at it, whatta ya know, it was plugged. Clip off the end, and vroom.
KLRFan is offline  
post #7 of 7 Old 02-11-2009, 02:34 PM
2nd Gear
kent soignier's Avatar
Join Date: Nov 2007
Location: north Ga. USA
Posts: 272
is it the carb or electrical?

It's the carb. Most likley.
I agree with the pilot (idle circuit) jet theory. It is probably stopped up, it is a tiny hole. It is only the pilot jet, the main jet has zero to do with the way the bike runs at idle. Also, the passage that feeds the idle mixture adjustment can get partially or fully blocked. While you are in the area, you may want to remove the plug covering the fuel screw so you can adjust idle mixture.
And yes, it could also be a plugged vent tube, I have seen dirt dobbers stop them up. Very easy to check, remove it and see if you can blow thru it.
But, if it was running and idling when it was parked a few months ago, the idle jet is the most likely problem.
On a hot day, with the engine hot, then you park the bike; the fuel can boil in the float bowl. this starts the cooking. In relatively short time.As fuel evaporates from small quantities like a float bowl's worth, it leaves behind residue that can easily clog the jet.

'08 KLR650,
'72 BMW R75/5 (Col. Klink),
'02 KTM 400 E/XC,
'05 ktm 125 sx (for sale)

"Hey, are you okay? Can you get up?
I thought you said you could ride"

All the best
Kent Soignier
the str8ner
kent soignier is offline  
Sponsored Links

Quick Reply

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


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

Email Address:


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
'08 electrical schematic ScareCrow 2008+ KLR650 Wrenching & Mod Questions 1 12-06-2008 12:01 PM
89 electrical problem George 1987 to 2007 Wrenching & Mods 0 01-23-2008 09:00 AM
Electrical fuzz tommen 1987 to 2007 Wrenching & Mods 6 10-10-2007 03:54 PM
Electrical Problems Fester 1987 to 2007 Wrenching & Mods 5 07-27-2007 05:51 PM
Electrical problems MotoPhoto 1987 to 2007 Wrenching & Mods 4 06-15-2007 05:48 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