Odd Stall-Out Tonight - Kawasaki KLR 650 Forum
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post #1 of 6 Old 09-23-2011, 12:35 AM Thread Starter
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Odd Stall-Out Tonight

Was on my way home from work tonight and had ridden about 10 miles when I felt something weird going on with the KLR and realized it was slowly losing power. By the time I got off the side of the road, it just died; still had power and lights but wouldn't run.

I shut it down and took off my helmet and gloves and checked the kill switch, etc., but the dragged-out loss of power and the dying felt like it was the result of a bad fuel flow. I only had 170 miles on the tank so knew it wasn't that. I tried starting it a couple of times. It would crank but wouldn't catch.

Just for the hell of it, I reached down and turned the petcock to reserve and then back to on.

When I tried starting it again, it fired right up and I made it home the remaining 30 miles or so without incident and it seemed to be running just fine. Lost my earplugs in the dark, though, which sucked. Finishing that ride without them made me realize how great they are.

Anyway, anybody have any idea what might have caused this? I'm going to check my petcock vacuum line tomorrow to make sure it's good and maybe run some Seafoam through the tank when I fill up tomorrow.

Glad it started up again because my wife would have been pissed if she'd had to get up and come get me. She has to get up at 4 in the morning.



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post #2 of 6 Old 09-23-2011, 02:47 AM
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How much fuel was in it? If it was really low, with you moving side to side you might of had moved some fuel over to the left side and giving you a running out of gas symptoms. If you had plenty of gas, you might have dirt in carb blocking flow. Both of these happened to me before.

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post #3 of 6 Old 09-23-2011, 06:33 AM
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I'd vote for vacuum problems. Either in the petcock vacuum system or the gas cap vent system. I had similar problems (with both), shortened the vacuum line to the petcock (to eliminate a kink) and shot some silicone through the cap vent to lube the little diaphram and keep it from sticking.
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post #4 of 6 Old 09-23-2011, 07:00 AM
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Just a wild guess, but . . . could you possibly have been low on fuel, expending that in the main tank; then . . . when you switched to RESERVE, provided adequate fuel to finish your journey?

The symptoms you describe seem consistent with that scenario, to me.

"Vacuum-actuated petcock problems?" Not likely, since . . . the SAME system supports the reserve fuel supply as it does from the main tank.

How much fuel was required to top-off the tank after your incident? A clue may reside there.
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post #5 of 6 Old 09-23-2011, 07:49 AM Thread Starter
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Morning After Thoughts:

Thanks for the replies. I should have noted that when I messed with the petcock, it was just a quick turn to "RES" and then back to "ON." I rode the rest of the way home with the petcock in the "ON" position. It was on "RES" for maybe a second before I turned it back to "ON."

My fiddling with the petcock and the subsequent starting might have just been coincidence, but it's the only thing I did before it started again.

I'd just refilled and reset my trip meter 3 days before and I had 170 miles on that tank so I wasn't running on fumes or anything.

Hadn't thought of the cap vent.



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post #6 of 6 Old 09-23-2011, 09:02 AM Thread Starter
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Well, may have found a clue; maybe not.

I was messing around with the petcock fuel/vacuum lines and while doing so, the fuel line came loose from the petcock.

Where the fuel line attaches to the petcock, there's a metal elbow. This elbow fits into a hole on the back of the petcock. The actual metal elbow came loose and all the way out of the hole in the petcock when I tugged on the fuel line. It just seemed to be a friction fit when I pushed it back in, but it seems suspect. I was pulling down on the line, but to pull that elbow out of the petcock, you would have to pull it to the rear. I'm wondering if maybe it was just barely seated?

Is this normal? I'm wondering if it didn't back out of that hole enough last night that for some reason the flow of fuel was disrupted and my fiddling around with it seated it again?

I've had the tank off a few times to do the .22 mod and most recently to install a light, but I always disconnected the rubber fuel line from the petcock before removing the tank.

I'm think something's not right with that petcock fuel line elbow, but am not sure. It seems to be designed to pivot a little bit? Should I just be able to pull it out with my fingers and very little effort?



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