Surging Again - 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 54 Old 11-05-2009, 07:54 PM Thread Starter
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Surging Again

My KLR is five years old and from time to time I experience surging at highway speeds. Last week I took a two hour ride that ended up with continual, and heavy surging to extent I didn't know if she would get me home.

I gave her full choke to see if it was fuel starving. Nope. I opened up the fuel tank cap to see if there was a vacuum problem. Nope.

Over the years I've removed the tank, checked for debri in the lines and everything I could think of. I'm going to fiddle with her a bit more but it seems as though it's time to abandone my favorite bike. I hate to but I'm at wits end.

My other bit is a trusty old 1985 BMW that's very dependable. May have to go back to that.

I'd appreciate any assistance. I know KLR's are famous for surging and was wondering if anyone has found the magic cure.

Joe
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post #2 of 54 Old 11-05-2009, 08:18 PM
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If you haven't adjusted the idle mixture screw it's time to do it. You may also consider doing the 22 cent mod.
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post #3 of 54 Old 11-05-2009, 08:28 PM Thread Starter
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SLO

Thanks for the suggestions. I don't know anything about the 22 cent mod.
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post #4 of 54 Old 11-05-2009, 08:36 PM
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The idle should be 2 to 2.5 turns out from lightly seated.
The 22c mod is just 2 #4 stainless washers slid onto the carb needle.
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post #5 of 54 Old 11-05-2009, 08:43 PM Thread Starter
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Thanks Slo,

I'll give it a try.

J
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post #6 of 54 Old 11-06-2009, 12:41 AM
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try the petcock mod too. sounds stupid, but has solved a lot of fuel delivery problems. maybe check your main jet too while you have the carb apart.

02 klr - heated vest and grips, corbin dished, EM doo, petcock mod, MB PCV mod, stainless oil filter, bash plate, mayher hand guards, low mount fender, power socket, tall windscreen, jardine exhaust, jetted, studebaker shifter, magnetic plug, airbox mod, k&N, kenda knobbies, DIY pelicans, HID light
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post #7 of 54 Old 11-06-2009, 04:53 AM Thread Starter
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Surging Again

Thanks Fellows,

This is the craziest mal-function I've ever seen. In the past I thought it was due to heat because it only happened during those hot summer days but the weather is pleasantly cool. And what further makes no sence, if I'm crusing at fifty or sixty mph with surges, if I wick it up to eighty or more she smooth right out. Also there doesn't seem to be any problems at forty or slower.

Does anyone know if the later models still have this problem. Perhaps I could just buy another Carb.

Riding alone, across the southern Texas panhandle last year, and wondering if I'd make it across, I swore this was the last. It's a love hate relationship.

Ok, now the tank comes, the fuel system dismantled for the last time. Everyting about this bike is close to perfect for me. I don't know where I'll go from her. Perhaps a DR.

Joe

Joe
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post #8 of 54 Old 11-06-2009, 09:45 AM
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Ummm....
Pics of the 85' BMW, please??



My KLR did the same thing and it was the idle mixture screw. I went 3 turns out.. Never had an issue with it again, and that was 3-4 years ago.
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post #9 of 54 Old 11-06-2009, 03:24 PM Thread Starter
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Paper,

Thanks for the infor about the idle mixture screw. That's so easy and will be my first attempt. It makes sence this could solve the problem.

Are any of you guys like me, when a bike is acting up I can't enjoy the my ride. The mind can't disreguard the problem. When on a four or five day it's a compromise situation

I'll take a couple of snaps of my K-bike and forward them. I really like that bike and it's a dream on the long hall but is't a highway bike only. It would be hard for me to get away from the 21" front wheel of my KLR. Of all the bikes I've look at as a replacement, few of them are as road and off road ready.

My little bike cruses, sweet spot, at 80mph but in reality the GPS has me clocked out 69mph. That's fast enough for me but the speedo is a little off. I'm sure it's save me from speeding tickets.

Joe Crumley
www.normansignco.com
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post #10 of 54 Old 11-06-2009, 03:31 PM
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Joe,

Check the vacuum line from the intake manifold to the petcock. This vacuum line breaks down and crimps at the intake manifold. The crimping causes vacuum loss which causes the petcock diaphram to not open all the way which limits the amount of gasoline getting to the carburetor. A new longer vacuum line routed over the top of the carburetor will not hurt. The rerouting prevents the vacuum line from crimping.

I eventually converted my petcock to manual and this helped a lot.

The 22 cent mod is a good solution for more than one reason. You don't have to use two #4 stainless steel washers though you might end up with both. Not all #4 SS washers are the same thickness. I have measured them from .023" to .036". Cary Aspy recommended not using more than .060". If you need .060" you need to look into the KLX needle or DynoJet needle mods. Radio Shack sells #4 stainless washers.

Sea-Foam: before you do anything add some Sea-Foam to a full tank of gasoline and run at least five gallons of the tank.

Air cleaner: have you cleaner and oiled your air cleaner? Don't over oil the filter.

Fuel line: check your fuel line. You might want to replace it. I recently replaced mine because it was breaking down inside.

Gas Tank Seal: I removed the seal from my gas tank which allows the tank to breath (vent).

Hope this helps.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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