Never Ending Fix It Quest - Part "Sputtering" - 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 12 Old 05-09-2019, 02:22 PM Thread Starter
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Never Ending Fix It Quest - Part "Sputtering"

Here's the latest iteration:

High RPMs highway travel, when its >75* outside, >4000 RPMs, with the 16 tooth front - 60mph indicated or higher, it starts cutting out like I'm running out of gas. Even with a full tank. Its almost like there's a piece of trash or something in the main jet. I've taken the whole thing apart from the tank to the carburetor and its clean. Jets are spotless, no indication of anything in the bowl. The diaphram is intact up top and the seal is still good.

I've just ever so slightly raised the fuel float level and I haven't tried that out yet. The only thing I can think of is that I added the 2nd washer of the 22 cent mod in December and maybe, whatever. That's the only thing I can come up with. What do you think?

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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post #2 of 12 Old 05-09-2019, 03:26 PM
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I've had a couple of atv carbs that people had forgotten the needle jet above the main emulsion tube & didn't run for crap. Then they found it & installed it.
Then they still seemed too rich/sputtery on main jet even with altitude appropriate main jet.

Some liquid teflon thread sealant on the emulsion tube threads stopped fuel from passing around the threads.

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post #3 of 12 Old 05-09-2019, 03:27 PM
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Have you tried riding with the gas cap cracked open? Perhaps the umbrella seals are sticking which would create a vacuum in the tank and not allow sufficient fuel to flow under those conditions.
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post #4 of 12 Old 05-09-2019, 05:06 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Have you tried riding with the gas cap cracked open? Perhaps the umbrella seals are sticking which would create a vacuum in the tank and not allow sufficient fuel to flow under those conditions.
I have not tried that. I will try that, after I try this latest iteration of float adjustment in about 5 minutes.

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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post #5 of 12 Old 05-09-2019, 05:15 PM
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Gas cap vent would be my first thought too....you don't have an aftermarket fuel filter do you? After that it'd be checking carb and jet installation.

Dave
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post #6 of 12 Old 05-10-2019, 12:54 PM
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I have seen some 'rough texture' or imperfections in the sealing surface of a couple of the black plastic Carb Tops which seals the diaphragm vacuum chamber.
If the carb top was rotated the imprint of the imperfection could be in a different location.

If there is any vacuum leakage for any reason from that carb top they usually start stuttering by 4000 and will Not rev over 5000.

pdwestman
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post #7 of 12 Old 05-15-2019, 08:08 AM Thread Starter
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Just completed about a 600 mile road trip on it. I'm convinced its a tank vent issue. The issue starts occurring with about 2 gallons left in the tank and you feel like its hitting reserve time. The last time it happened I cracked the tank cap open and kept on going without needing to be in reserve. So there we have it, its a vent issue. But now I have a new fuel line and inline filter too.

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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post #8 of 12 Old 05-15-2019, 11:01 AM
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If one uses an empty Visine bottle or something similar to create a vacuum on the fuel tap automatic diaphragm hose or has a manual valve, one could time how long it takes to drain the 5 - 5.5 gallons of normally level accessible fuel like on a flat straight highway.

If fuel flow slows or stops, 1st check that the Visine bottle still has vacuum. Then open fuel cap, if needed.

One could temporarily use empty, clean milk or water jugs to measure time per each gallon. (They are actually larger than a gallon.)

The fuel system needs to flow at least 3 gallons per hour (1.2qt per 6 min) to sustain 30mpg @ 90mph in a head wind. My bike got 35mpg in similar conditions, twice.

Time this once with tap in the ON position & a second time in the Reserve position. (Is there any possible old fuel varnish restricting the internal fuel filter screens?)

pdwestman
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Last edited by pdwestman; 05-15-2019 at 11:06 AM.
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post #9 of 12 Old 05-16-2019, 02:01 PM Thread Starter
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So it did it again today. 60mph and sputter-sputter-fell on its face. 3 gallons of gas left in the tank. While I was still coasting I took the key out and cracked the fuel cap and it fired right up before I even got below 40mph. I just took the gas cap apart and it seems like this first rubber umbrella gets "stickier" as the ambient temp goes up. Blowing through it seems like it takes a little more force than should be necessary for a vacuum to breathe with it. That umbrella seal doesn't show to be its own part on the parts diagram. Guess I'll have to "improvise."

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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post #10 of 12 Old 05-16-2019, 03:05 PM
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....I love my IMS tanks. :-)

Dave
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