KLR 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 02-09-2020, 08:00 PM Thread Starter
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Join Date: Feb 2020
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KLR wont start

I have just bought a KLR 650 1999.

First post. Always wanted to own one.

Im 60, never been without a bike since I was ten , mostly old and crap so have some experience making them run.

One owner from new, 6500km, has not run for three years. He reported that the last time he rode it it was popping and banging as if the timing was off.

I put a new battery in, completely dismantled and reassembled carb - (it was clean inside, watched a great video series on here) Both diaphragms look good. Plugged the vacuum line at carb to the fuel petcock and took the spring and o ring out of the petcock.

The plastic fuel enricher attachment is broken off and has been siliconed, but right at the outside end where the cable outer fits in. I dont think its leaking air.

It sparks fine - spun over with plug out,

All I am getting are some impressive backfires and occasionally it fires once nicely.

Ordered a doohickey kit so will do that as soon as I get back, as well as a Vulcan petcock and a no cable choke kit.

Unfortunately I leave for work tomorrow for a couple of months, so thats it for now, but any ideas appreciated - particularly how I go about checking ECU.

Thanks , Charlie
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post #2 of 6 Old Yesterday, 10:31 AM
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Join Date: Nov 2009
Location: Lander, Wyoming
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Three other things that I would have done even before ensuring that the carburetor passageways Above the pilot jet were clean (did you see the 3 tiny holes under the bottom lip of the butterfly plate?).

#1, Inspect, clean & Re-Oil the foam air filter. inspect for dust inside the Clean Side of the air box.

#2, Measure the Cold Cranking Compression of engine with throttle Wide Open. (77-124 psi)

#3, Check spark strength with plug cap unscrewed from the coil wire, 7mm + of spark ? And install a brand new spark plug.

Wishing you Good Luck upon returning from work.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 6 Old Yesterday, 10:45 AM
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Join Date: Feb 2020
Location: Blue Ridge,GA
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Plug-even a bad one can spark outside,compression takes more umph.
Try a new plug-worked for me.
And drain float bowl and refill.
KLR is a VERY cold natured beast-after this use starting fluid sparingly.
Check choke adjustment at handlebar-mine tends to backoff.

Last edited by DustyRoads; Yesterday at 10:47 AM.
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post #4 of 6 Old Yesterday, 06:58 PM Thread Starter
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Join Date: Feb 2020
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Thanks for all the good suggestions. I had cleaned the air filter, and I think I got all the holes clean in the carb body.

I did get it to start after cleaning the plug again and gapping it. Sounded nice but did not want to accelerate and still cut out occasionally but it idled nicely at half enricher/ choke.

When I get back ill bring a new plug and plug cap. I think a good check of grounds and connections is in order.
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post #5 of 6 Old Yesterday, 10:06 PM
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Join Date: Nov 2009
Location: Lander, Wyoming
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Did you drain the ethanol gasoline from the carb before leaving for 60 days + of work?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #6 of 6 Old Yesterday, 10:14 PM Thread Starter
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Join Date: Feb 2020
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I did. I was using 100low lead avgas which has no ethanol in it but i drained it anyway.
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