Engine stops running on hot days - 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 5 Old 10-04-2019, 05:01 PM Thread Starter
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Angry Engine stops running on hot days

I am new to the KLR 650, had my 2003 for two months. Strange problem, cruising along at road speed, it will suddenly stop running for several seconds, then start back up. If I come to a stop, it will restart after only a couple of minutes. Have checked the gas, no water or sediment. Maybe some intermittent ignition problem, or fuel pump problem caused by 90+ degree temperature???
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post #2 of 5 Old 10-04-2019, 05:42 PM
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Fuel tank cap vent holes occluded (stopped up) a possibility; ain't got no stinkin' fuel pump--gravity feed.

Possibly, petcock (fuel tank valve) problem; vacuum-activated OEM part sometimes cranky.

Next time this happens; open fuel tank cap and see if this procedure makes a difference; if so, vent problem likely.
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post #3 of 5 Old 10-06-2019, 09:22 AM
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Mine did that after I put front crash bars on. I had to remove the tank and after reinstalling the tank, I partially kinked the/one of the pet-cock vacum lines.
I have since deleted the vac part of the pet- cock and havent had a problem since
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post #4 of 5 Old 10-09-2019, 06:35 PM
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Quote:
Originally Posted by Damocles View Post
Fuel tank cap vent holes occluded (stopped up) a possibility; ain't got no stinkin' fuel pump--gravity feed.

Possibly, petcock (fuel tank valve) problem; vacuum-activated OEM part sometimes cranky.

Next time this happens; open fuel tank cap and see if this procedure makes a difference; if so, vent problem likely.
I also have a 2003 KLR and agree with Damocles, though I'd take the lazy route and run a tank full of non-oxy gas mixed with a can of Sea Foam through the bike first. If that helps, do it again and then go back to running regular gas. If that's no help then then look at the fuel cap and petcock. Another thought, did the previous owner install a fuel filter? If so, remove it. It's generally accepted that fuel filters on KLR's can cause more trouble than benefit.
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Last edited by Vgraf; 10-09-2019 at 06:37 PM.
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post #5 of 5 Old 10-14-2019, 08:42 PM
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Sounds very much like a kinked fuel/vacuum line especially if you have taken the tank off recently. You should be able to just see up under the tank and check the lines are not jammed up against something.
The bike will run absolutely normally until it just stops. Then start again and run normally until the next time. The regularity of it stopping then starting again after a certain time like clockwork confused me when it happened to me.

Someone else had the same thing happening on hot days/when the bike was running hot. Heat may make it happen a bit more. Not sure. KLRs always run hot in my experience.
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