2007 KLR Problem - 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 15 Old 09-12-2010, 09:41 AM Thread Starter
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Question 2007 KLR Problem

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2007 KLR Problem
on: Today at 0843 AM Quote Modify Remove

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Hi Guys

I need help to get my KLR650 running again. This morning i decided to do some work to the bike.
Its a 2007 KLR 650 with 9800 kilos on her.

I changed the oil, oil filter, cleaned air filter, changed the spark plug and lubed the chain. The started fine and rode bike to bike shop to warm the chain so in could apply some chain wax. On leaving bike shop, the bike would not start without full choke and when i left shop it would splutter and not rev. Then bike came right and hit the highway and bike rode well till i had to shut off, it was popping and back firing, then pulled up at the lights she died and would not start without the choke fully engaged.

Now the bike wont start but only using the choke. The choke must be all the way out and then she will fired and idle high, but as soon as you move the choke the bike dies. Which tells me its a fuel problem.

So i removed carb to check jets and its as clean as a whistle. Next stop fuel tap, clean and checked that vacuum was working by taking off the pipe from the carb and sucked and the fuel flows freely from the tap. The pipes cant be on the wrong way as they are different size pipes for vacuum and fuel. I have checked pipes that there are no kinks and removed pipes and checked that there are no holes or leaks.

I tried again this morning, changed the spark plug back to the old one, still no luck. Secondly filled bottle with petrol and blocked vacuum line. Still wont start except with choke. So started bike with choke and let it idle a 3000 rpm till warm, then turned idle screw all the way in and turned off the choke, bike barely idles and very rough at 1500 rpm. Took off air filter,still wont idle with out choke fully engaged.

When bike was idling, with choke and or idle screw fully turned in, if u blip the throttle, the bike splutters and back fires then dies. I can only think its fuel related, removed the carb and and checked, no dirt in carb will take to work tomorrow and remove all jets and blow clean with compressed air and try again.

Any other thoughts guys?


Thanks
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post #2 of 15 Old 09-12-2010, 10:39 AM
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Possibly too much oil on the air filter??
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post #3 of 15 Old 09-12-2010, 10:41 AM Thread Starter
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I tried without air filter, still no joy.
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post #4 of 15 Old 09-12-2010, 10:43 AM
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Did it run fine before you did the service to it?
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post #5 of 15 Old 09-12-2010, 10:46 AM Thread Starter
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Yes run very well. I checked everything i touched and all i was ok, so my guess its dirt from the air filter that has gotten into a jet or passage. Will try cleaning it and then try again.
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post #6 of 15 Old 09-12-2010, 10:52 AM
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If it ran before, it's got to be something that you did or maybe bumped during the service. If you took the tank off to change the plug, I'd check your vacuum lines to the petcock to verify that they're on and the carb is getting all the gas it needs.. If one is kinked it's only getting partial vacuum and only allowing part of the fuel needed to the carb. That would keep it from actually reving, and with the choke on, you're limiting air, which would explain why it's only running with it on.

Just a thought..

Anyway, take your time and give everything a good once over. It's bound to be something simple if it was running fine before..
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post #7 of 15 Old 09-12-2010, 10:58 AM Thread Starter
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Well i went through everything 3 times, no kinks in pipes, fuel tap works, vacuum works to carb, vacuum operates fuel tap, changed spark plug back to original, took off air filter in case i over oiled filter, still no joy. But after i did service it ran ok for a while like 2 miles then it started when i stopped and restarted to go home so i guess its got something to do with fuel. blocke jet or something
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post #8 of 15 Old 09-12-2010, 11:01 AM
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See how it runs with the gas cap left cracked open to eliminate a venting issue.
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post #9 of 15 Old 09-12-2010, 11:04 AM Thread Starter
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Will try that once i have cleaned carb tomorrow with compressed air.
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post #10 of 15 Old 09-12-2010, 11:05 AM
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Good luck and sometimes walking away for a while seems to help.
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