Will the .22 mod fix my new issue? - 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 7 Old 12-18-2019, 04:42 PM Thread Starter
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Will the .22 mod fix my new issue?

Over the weekend I did some work on my 1999 KLR. I installed the Thermo Bob two and the eagle Doohickey. I also installed oxford heated grips. All three projects went without drama. I then installed a new NGK spark plug. I went with the same plug range that was already in there. DPR8EA-9. The last thing I did was change out the foam air filter. The one that was in there was pretty dirty. So I oiled up a new one and installed.

I should note that the spark plug I pulled out was a very light tan color almost an indication of the bike running lean. However prior to doing all of this the bike ran just fine.

Now the problem: after getting everything put back into place I started up the bike and let it warm up. It idles just fine, but when I rev it up it backfires and pops. Pretty much anything over 3500 and it does nothing but backfire and pop.

My thought is that with the new air filter allowing more air in that I now have an extremely lean condition. I’m hoping the 22 cent mod will correct this problem. Thoughts from the group? Thanks!
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post #2 of 7 Old 12-18-2019, 05:01 PM
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Thoughts;

- 1) light tan is usually considered good; white is typically considered lean but with all the additives in today's fuel, I'd suggest that plug color isn't a very reliable indicator of the proper jetting

- 2) nothing you did, including the filter change should affect jetting. Assuming everything else is stock (no airbox mods, snorkle in place, etc.) then something is up. Check for air leaks on the intake side and exhaust leaks as well.

....did you do anything else you haven't mentioned prior to the backfire/popping issues?

Lastly, stock will work fine, the 22 cent mod is a bandaid that helps but the real cure to KLR jetting is a KLX kit (available from Eaglemike) and removal of the intake snorkle. ....but I'd want to know what is going on before messing with jetting because it shouldn't run like that even with stock jetting.


Dave
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post #3 of 7 Old 12-18-2019, 05:25 PM Thread Starter
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I’ve done some more research online. I’m starting to think that I may have pinched the vacuum line to the fuel petcock when I reassembled everything. I have the fuel tank off to replace the spark plug. Tomorrow I’m going to pull the fuel tank back off and make sure the vacuum line is not pinched.
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post #4 of 7 Old 12-18-2019, 05:31 PM
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good thought; I always figure it has something to do with recent work.....sometimes not but usually....


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post #5 of 7 Old 12-18-2019, 06:36 PM
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Quote:
Originally Posted by Kurt V View Post
Over the weekend I did some work on my 1999 KLR. I installed the Thermo Bob two and the eagle Doohickey. I also installed oxford heated grips. All three projects went without drama. I then installed a new NGK spark plug. I went with the same plug range that was already in there. DPR8EA-9. The last thing I did was change out the foam air filter. The one that was in there was pretty dirty. So I oiled up a new one and installed.

I should note that the spark plug I pulled out was a very light tan color almost an indication of the bike running lean. However prior to doing all of this the bike ran just fine.

Now the problem: after getting everything put back into place I started up the bike and let it warm up. It idles just fine, but when I rev it up it backfires and pops. Pretty much anything over 3500 and it does nothing but backfire and pop.

My thought is that with the new air filter allowing more air in that I now have an extremely lean condition. I’m hoping the 22 cent mod will correct this problem. Thoughts from the group? Thanks!
Sounds like the new plug is bad outa the box to me. (did you check the gap)

or

the needle is on top of the white needle retainer where it should be under

or

you tapped the heated grips into the wrong place

or

diaphragm damaged

Last edited by KLR Jo; 12-18-2019 at 06:41 PM.
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post #6 of 7 Old 12-18-2019, 07:33 PM
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Have you felt for exhaust leakage around the header pipe to head connection? Very common to have loose exhaust header flange nuts which allows the header gasket to burn thru, which allows air into exhaust header, which causes exhaust after-fire/popping.

You may simply need a new exhaust header gasket.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #7 of 7 Old 12-19-2019, 03:59 PM Thread Starter
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Join Date: Oct 2019
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Update to my thread. I hate it when somebody doesnít post the resolution to their problem. Anyways, I did the $.22 mod, put in a new spark plug and made sure the vacuum line to the petcock was clear and had a good fit. One, or all of these fixed the problem!
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