Carb problem: Overheat, stuck-RPM, IDLE-jumps - 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 3 Old 06-13-2017, 10:07 AM Thread Starter
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Join Date: Apr 2017
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Carb problem: Overheat, stuck-RPM, IDLE-jumps

Hi,

Engine on my KLR behaves strange now. My idle RPM is floating. I set it to 1300 as it's listed in manual, but quite often it goes to 2000 and then stuck there. Then it can go back randomly. This leads to overheat, backfire and unstable start - bike dies without a choke when it's cold and by cold I mean normal +25 around. Also on idle I hear not backfire, but some sort of piu-piu sounds. Because of backfire and overheat I thought that it runs too lean, but adjusting a pilot screw half turn out didn't solved the problem and seems made it even worse. Also my fuel consumption is weird now.
I want to take carb off and clean it, but which parts should I check first? Main jet? Maybe slider stucks in opened position? Friend of mine also told that it looks like bike suck air through manifold, but I can't find a new part for my KLR600. Please, give me your hints.
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post #2 of 3 Old 06-13-2017, 11:52 AM
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Quote:
Originally Posted by everm1nd View Post
Hi,

Engine on my KLR behaves strange now. My idle RPM is floating. I set it to 1300 as it's listed in manual, but quite often it goes to 2000 and then stuck there. Then it can go back randomly. This leads to overheat, backfire and unstable start - bike dies without a choke when it's cold and by cold I mean normal +25 around. Also on idle I hear not backfire, but some sort of piu-piu sounds. Because of backfire and overheat I thought that it runs too lean, but adjusting a pilot screw half turn out didn't solved the problem and seems made it even worse. Also my fuel consumption is weird now.
I want to take carb off and clean it, but which parts should I check first? Main jet? Maybe slider stucks in opened position? Friend of mine also told that it looks like bike suck air through manifold, but I can't find a new part for my KLR600. Please, give me your hints.
You could use an Un-Lit butane lighter or propane torch to check for vacuum leaks thru the rubber intake manifold or under loose clamps.
Pilot jet and pilot mixture screw and the 3 tiny little pilot outlet holes at the bottom edge of the throttle plate are probably the most likely issues.

Read and understand this link, Care & Feeding Of The Keihin Carb

The 'afterfire'/popping out of the muffler will be exaggerated by lean pilot carburation and possibly the small air cut-off diaphragm on the LH side of the carb. Also an bad gasket at the cylinder head/exhaust header connection will cause 'afterfire' popping.

In the USA K part # 16065-1104 intake manifold/carb holder is still available for $76.00 usd.
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post #3 of 3 Old 06-15-2017, 06:46 PM Thread Starter
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Join Date: Apr 2017
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Thanks for your reply! I disassembled my carb today and it looks pretty clean. The only part I noticed missing is small rubber ring after a washer of pilot jet. Do I really-really need it, or it will work without this tiny guy? I've cleaned all the parts and will try to see how it runs tomorrow.
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