Stuttering and popping through exhaust - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

  • 2 Post By Kurt V
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post #1 of 6 Old 02-09-2020, 04:44 PM Thread Starter
Join Date: Oct 2019
Location: Lincoln,NE
Posts: 13
Stuttering and popping through exhaust

After doing some modifications on my 1999 I have gone from having a smooth running engine to one that continuously stutters and pops in the exhaust anytime you try to rev it above 2000 RPM. Along with that the tach bounces all over the place bouncing from zero to redline.

I made several modifications at one time so itís hard to figure out which one led me to this problem.

The modifications I made were: Doohickey, Thermo Bob, $.22 mod along with drilling the slide, and heated grips.

What I have done to try and resolve the problem: removed the $.22 washer, disconnected the heated grips and made sure I had good battery ground. I double checked to make sure the slide diaphragm had no tears in it. No change in the sputtering and popping.

The battery is strong and holds a charge. The bike easily starts and idles well.

I had fresh gas in the tank, but I have drained it out and am going to put fresh gas in.

I keep thinking that with the tach bouncing all over the place it must be something electrical. But looking back through the forum the only suggestion anyone has is check your grounds. Which I have done. I have even added an additional ground, but with no improvement.

I know it has to be something simple, the solution evades me.
Kurt V is offline  
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post #2 of 6 Old 02-09-2020, 04:55 PM
1st Gear
Join Date: May 2017
Location: Concord, MA
Posts: 88
I know you said you checked the grounds but did you check to make sure the battery connection at the terminals were right? First thing I'd do is make sure the little nut is still under the negative terminal and tighten it up. Start there.

2007 KLR
JTCrow is offline  
post #3 of 6 Old 02-09-2020, 05:01 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,195
You might ought to look for wire damage near the engine sprocket, being as you recently disturbed them.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #4 of 6 Old 02-09-2020, 05:08 PM Thread Starter
Join Date: Oct 2019
Location: Lincoln,NE
Posts: 13
Connections at the battery terminal are clean and tight. I didnít think about checking the wires down by the engine sprocket. Iíll take a look at that tomorrow.
Kurt V is offline  
post #5 of 6 Old 02-10-2020, 09:30 AM
Join Date: Feb 2020
Location: Blue Ridge,GA
Posts: 4

Try a new sparkplug&drain and refill floatbowl.
DustyRoads is offline  
post #6 of 6 Old 02-15-2020, 04:19 PM Thread Starter
Join Date: Oct 2019
Location: Lincoln,NE
Posts: 13
Problem resolved! Turns out that one of the two wires that connect to the coil was barely attached. Cleaned ed the connection, reattached wire and everything is back to normal!
pdwestman and 89a3 like this.
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