HEELLLLPPP -Starts fine but dies when throttle engaged - 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 21 Old 07-06-2017, 12:59 AM Thread Starter
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HEELLLLPPP -Starts fine but dies when throttle engaged

Hi Everyone,

Need HEEEELLLPPP on my trip to the end of the world...stranded in Seattle :/

Apologies ahead of time as I am sure this post is on the forum in some form or fashion, but of course my issue is unique and also sorry for writing such an essay.

Start of Issues:
While riding, the bike died all of a sudden without any sputtering or anything. Naturally, sounds electrical. So long story short, after testing the spark plug and realizing that it wasn't getting a spark, i started to test all of the electrical nodes in the ignition system with the multimeter. Eventually found a spliced wire coming from the stator (got caught in my chain / sprocket?) and then I soldered it together and spark returned. Got the bike started and then the new issue started...

Current issue...
After riding a few miles after fixing above issue, the engine started to sputter in low RPMs, so I would play with the clutch, get the rpm's up and then the bike would run fine. I rode on the freeway for about 60+ miles to get to a friends house. When I got off the freeway, the RPMs dropped and the bike immediately shut off. Once I came to a stop, I put the bike in neutral and started it back up, it died again when i tried to give it gas, so i kept the RPM's high by using the clutch and feathering throttle during the 5 or so city miles to my friends. Last mile or so, bike seemed to be working fine without any sputtering or anything in lower RPMs, weirdly inconsistent.

I then let the bike sit for a couple days as I was busy in the city. I went to start the bike again and give it a test ride. First .5 mile, bike seemed fine, then the sputtering in lower RPMs in gear 1 &2 started and I had to nurse it back home by playing with clutch, been working on it ever since.

What i've done:
- Rechecked all ignition electronics and everything looks good - no pinched wires, nothing grounding, etc.
- Inspect all fuel lines and vents for leakages - none found, good gas in fuel lines and float bowl
- Took petcock apart - nothing of warning in there, all filters in tact, gaskets in good condition, valve clear, etc.
- Inspected the throttle cables - in good order
- Took carb out and cleaned all jets, float bowl, etc. - looking like new and everything is clean or undamaged including air cutoff valve and slide diaphragm
- Thinking electrical issue again, replaced the spark plug and tested - good spark and electrical flow resulted
- Checked the choke/enricher play - appears to be opening and closing as it should
- Air filter - was extremely dirty (6k miles on it on this trip so far with 35% dirt) so replaced with brand new one
- Checked fuel tank cap - Appears fine but What does it mean when it is hissing?

Tried to start the bike again and it ignited just fine with choke engaged, let it warm up for a couple minutes, disengaged choke, then it idled fine for a couple minutes so I went to give it gas in neutral. Once I gave it gas, it sputtered and died quickly. Then was curious to see what the spark plug was doing (due to above issue) and it was covered in black soot (carb fouled) Why would it be like that after one start of the bike? Clymer says because it's running rich, so I leaned out using the Pilot Mixture Screw.

Started bike again and then it died again when giving gas...

Now, I am at my whits end...Anyone have any idea what is going on?

Cheers and thank you!!

Lars
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post #2 of 21 Old 07-06-2017, 08:24 AM
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Ugh?

The gurus will be awake soon.......
You have done what I would have.
Do all that testing and changing out some basics,
then come to this site. lol

It's either starving intermittently due to a possible vacuum leak,
or an electrical booger in the system. My hoses starting deteriorating
quite rapidly after purchase of my '09 new. Within 5 years all rubber
had been replaced.

Hope ya get it running happy mega-soon,
CheapMark

This is my son, with whom I am well pleased." ----God
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post #3 of 21 Old 07-06-2017, 09:41 AM
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You've said diaphragm is o.k.; is it SEALED properly? In its groove around the perimeter?

Symptoms suggest diaphragm air leak; however, you've certified a sound diaphragm.
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post #4 of 21 Old 07-06-2017, 10:32 AM Thread Starter
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Thanks!! Yeah, I am just getting up and back into it. Hoses looked fine yesterday but will recheck more thoroughly today and let you know.
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post #5 of 21 Old 07-06-2017, 10:36 AM Thread Starter
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Damocles - I believe so but will verify this morning, Also thinking that the spring seat might be covering one of the holes. First order of business as far as the carb goes. Then, going to take apart fuel tank cap, then recheck the air intake tube and finally play with lean and rich mixtures, draining gas each time. Not sure if draining the gas each time will help but just want to start from scratch
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post #6 of 21 Old 07-06-2017, 02:33 PM Thread Starter
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Hey guys, quick update. I have tried everything i mentioned I would ...

1. Slide diaphragm properly seated
2. Spring seat not covering holes
3. Gas cap vents clear - tore apart and sprayed with compressed air
4. Air intake tube is undamaged and not leaking
5. Air filter - rechecked and installed properly and is clean
6. Choke cable - working and seated properly
7. Stator cable (from previous electrical issue) in working order
8. Testing different richness during ignition with both choke on and off
a. Tested pilot screw at 1.25 turns - no distinguishable foul of spark plug
b. Tested pilot screw at 1.75 turns - spark plug then oil fouled
9. Just drained the float bowl and fuel line from petcock - about 2 oz. of fuel in there, is that too much? Is it flooding?

Each time i am trying to start the bike, it feels like the problem is getting worse, not better. Harder to start, symptoms on the spark plug are changing. Do I need to get into the top end at this point and do a compression test? Do I need to check the valves?

What else could be going on with this thing?
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post #7 of 21 Old 07-06-2017, 02:40 PM Thread Starter
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HELP!! - Mechanically Inclined Individual Needed ASAP Seattle

Hey Everyone,

Having troubles with my bike starting and not responding via throttle, and have gone through everything. See description below for details on progress..
.

Start of Issues:
While riding, the bike died all of a sudden without any sputtering or anything. Naturally, sounds electrical. So long story short, after testing the spark plug and realizing that it wasn't getting a spark, i started to test all of the electrical nodes in the ignition system with the multimeter. Eventually found a spliced wire coming from the stator (got caught in my chain / sprocket?) and then I soldered it together and spark returned. Got the bike started and then the new issue started...

Current issue...
After riding a few miles after fixing above issue, the engine started to sputter in low RPMs, so I would play with the clutch, get the rpm's up and then the bike would run fine. I rode on the freeway for about 60+ miles to get to a friends house. When I got off the freeway, the RPMs dropped and the bike immediately shut off. Once I came to a stop, I put the bike in neutral and started it back up, it died again when i tried to give it gas, so i kept the RPM's high by using the clutch and feathering throttle during the 5 or so city miles to my friends. Last mile or so, bike seemed to be working fine without any sputtering or anything in lower RPMs, weirdly inconsistent.

I then let the bike sit for a couple days as I was busy in the city. I went to start the bike again and give it a test ride. First .5 mile, bike seemed fine, then the sputtering in lower RPMs in gear 1 &2 started and I had to nurse it back home by playing with clutch, been working on it ever since.

What i've done:
- Rechecked all ignition electronics and everything looks good - no pinched wires, nothing grounding, etc.
- Inspect all fuel lines and vents for leakages - none found, good gas in fuel lines and float bowl
- Took petcock apart - nothing of warning in there, all filters in tact, gaskets in good condition, valve clear, etc.
- Inspected the throttle cables - in good order
- Took carb out and cleaned all jets, float bowl, etc. - looking like new and everything is clean or undamaged including air cutoff valve and slide diaphragm
- Thinking electrical issue again, replaced the spark plug and tested - good spark and electrical flow resulted
- Checked the choke/enricher play - appears to be opening and closing as it should
- Air filter - was extremely dirty (6k miles on it on this trip so far with 35% dirt) so replaced with brand new one
- Checked fuel tank cap - Appears fine but What does it mean when it is hissing?

Tried to start the bike again and it ignited just fine with choke engaged, let it warm up for a couple minutes, disengaged choke, then it idled fine for a couple minutes so I went to give it gas in neutral. Once I gave it gas, it sputtered and died quickly. Then was curious to see what the spark plug was doing (due to above issue) and it was covered in black soot (carb fouled) Why would it be like that after one start of the bike? Clymer says because it's running rich, so I leaned out using the Pilot Mixture Screw.

Started bike again and then it died again when giving gas...


I am willing to pay via beer or a reasonable charge for someone who knows their way around an issue like this. Need to be on the road by Saturday / Sunday at the latest. On a long trip and am pretty desperate at this point.

Anyone out there that may be able to help?

Thanks!!

Lars
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post #8 of 21 Old 07-06-2017, 03:39 PM
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A Hissing Gas Cap?

The Vent to the Fuel Tank is plugged! I really don't care what you've looked at, tested, blown compressed air through, etc. A hissing gas cap means the vent "circuit" of the gas tank is blocked somewhere! Emphasis here on the word "circuit;" By which I mean each and every every single part, large and small, obvious and hidden, of the vent system is a possible suspect. All components of the vent circuit should be assumed to be guilty until proven innocent.

Unlatch the Gas Cap and see if that doesn't immediately solve the problem. (Don't ride the bike around this way!) Diagnosis ONLY!

If opening the Gas Cap eliminates the problem; check the small hose(s) that come off the rear of the fuel tank near where the front of the seat contacts it. Trace it/them (depends on the emissions system on your bike) and make sure there are no kinks or pinch spots. Remember, if you are looking at this with the seat off the bike, THAT may be what is pinching a line! If your KLR has the vapor recovery system and all of the hoses look just fine, things can get a bit more complicated. But I'd start with the small hose(s) first as that is the most likely place to find the problem.

Last edited by Bluehighways; 07-06-2017 at 04:05 PM.
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post #9 of 21 Old 07-06-2017, 03:56 PM
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Quote:
Originally Posted by Larsgoesto View Post
Do I need to get into the top end at this point and do a compression test? Do I need to check the valves?
NO! Your problem is NOT mechanical inside the engine!
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post #10 of 21 Old 07-06-2017, 03:58 PM Thread Starter
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Quote:
Originally Posted by Bluehighways View Post
A Hissing Gas Cap?

The Vent to the Fuel Tank is plugged!

Unlatch the Gas Cap and see if that doesn't immediately solve the problem. (Don't ride the bike around this way!) Diagnosis ONLY!

If opening the Gas Cap eliminates the problem; check the small hose(s) that come off the rear of the fuel tank near where the front of the seat contacts it. Trace it/them (depends on the emissions system on your bike) and make sure there are no kinks or pinch spots. If your KLR has the vapor recovery system and all of the hoses look just fine, things can get a bit more complicated. But I'd start with the small hose(s) first as that is the most likely place to find the problem.
This is annoying how I can't just link to my other thread by the name of "HEELLLLPPP -Starts fine but dies when throttle engaged" but this is an update from that which I've been doing this morning...

Hey guys, quick update. I have tried everything i mentioned I would ...

1. Slide diaphragm properly seated
2. Spring seat not covering holes
3. Gas cap vents clear - tore apart and sprayed with compressed air
4. Air intake tube is undamaged and not leaking
5. Air filter - rechecked and installed properly and is clean
6. Choke cable - working and seated properly
7. Stator cable (from previous electrical issue) in working order
8. Testing different richness during ignition with both choke on and off
a. Tested pilot screw at 1.25 turns - no distinguishable foul of spark plug
b. Tested pilot screw at 1.75 turns - spark plug then oil fouled
9. Just drained the float bowl and fuel line from petcock - about 2 oz. of fuel in there, is that too much? Is it flooding?

Each time i am trying to start the bike, it feels like the problem is getting worse, not better. Harder to start, symptoms on the spark plug are changing. Do I need to get into the top end at this point and do a compression test? Do I need to check the valves?

What else could be going on with this thing?
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