Bike died and now wont 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 6 Old 08-10-2018, 01:15 PM Thread Starter
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Bike died and now wont start

Was riding around my neighborhood a little and all of the sudden the bike started shifting weird, and seemed almost jumpy. Then it died as if It had ran out of gas. It was on reserve because the petcock wasn't giving gas while it was on (I have plans to replace the vacuum line and rebuild the petcock). I could still see gas in the fuel filter when it died. Whenever I try to start it'll start for 2 seconds, then sputter out. Not sure whats going on, any help would be greatly appreciated.
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post #2 of 6 Old 08-10-2018, 02:36 PM
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I did a post recently about an easy and free mod to the petcock to get rid of the vacuum issue. Look it up, takes about 15 minutes with an empty tank.

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post #3 of 6 Old 08-10-2018, 04:21 PM
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Gas cap vent is clogged. I have an ims tank, so I actually just asked them for the vented cap option instead of OEM, but I suppose you could take your stock cap off and clean out the ports.

If you filled the tank it should make the problem go away for a bit but it'll come back as soon as you get back down to the same level. I don't know of any place to get aftermarket caps for the KLR except the ones that come with aftermarket tanks

Last edited by insan3guy; 08-10-2018 at 05:08 PM.
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post #4 of 6 Old 08-10-2018, 06:02 PM
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Shaky's Petcock Conversion above...

REALLY?!?! This issue is a gas tank vent thang?
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post #5 of 6 Old 08-10-2018, 06:23 PM
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The bike has symptoms of a clogged inlet valve from junk coming from the petcock or a clogged pilot circuit. In short, it isn't getting enough gas to even idle.

The clogged cap vent is also a good idea, but that usually results in a bike that will idle fine and will run at part throttle well but acts like it is running out of gas at speed. That one is easily diagnosed by running with the cap open. It should run fine at idle though, and yours isn't.

Were it mine, I'd pull the fuel line and, applying vacuum to the vacuum line, dump a pint of fuel into a jar. Look for little black pieces of crap.

Pull the carb and remove the float and valve and look for blockage at the inlet, then pull the pilot jet and look for blockage in it. You should be able to see light from end to end, though the passageway is only about .015" in diameter. It's a wee hole...

Check the entire pilot circuit, making sure that fluid will pass from the pilot jet area to the three holes in the intake side of the carb venturi. WD40 can be sprayed through the circuit, though anything you have to spray through there will work.
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post #6 of 6 Old 08-11-2018, 12:40 PM
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Try the simplest solution first. Add some gas to the tank.
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