My KLR stalls at high RPM - Kawasaki KLR 650 Forum
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post #1 of 8 Old 06-07-2012, 05:57 PM Thread Starter
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My KLR stalls at high RPM

My 09 KLR recently began cutting out at high RPM. I have drained the tank, ran carb cleaner through it, cleaned the air filter, cleaned the muffler and it still won't rev beyond 3000 before stalling(but idles fine). I recently purchased a Clymer manual and read about the float being out of adjustment....I was about to pull the carb off but decided to check the overflow drain tube from the carb. I simply blew into it and sucked with a small amount of force. The tube gurgled a bit but seemed to have no restrictions. I then started the bike and to my suprise it ran perfect. I grabbed my helmet and took off for a test ride....after about 10 minutes of easy riding through gears and RPMs it still ran great but shortly after punching the throttle to climb a big hill it began cutting out again. I repeated the process of blowing and sucking into the overflow tube and it cleared once again allowing me to make it home without issue. Any clues as to what the underlying problem is and how to fix it? Thanks!
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post #2 of 8 Old 06-07-2012, 08:04 PM
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My 09 KLR recently began cutting out at high RPM. I have drained the tank, ran carb cleaner through it, cleaned the air filter, cleaned the muffler and it still won't rev beyond 3000 before stalling(but idles fine). I recently purchased a Clymer manual and read about the float being out of adjustment....I was about to pull the carb off but decided to check the overflow drain tube from the carb. I simply blew into it and sucked with a small amount of force. The tube gurgled a bit but seemed to have no restrictions. I then started the bike and to my suprise it ran perfect. I grabbed my helmet and took off for a test ride....after about 10 minutes of easy riding through gears and RPMs it still ran great but shortly after punching the throttle to climb a big hill it began cutting out again. I repeated the process of blowing and sucking into the overflow tube and it cleared once again allowing me to make it home without issue. Any clues as to what the underlying problem is and how to fix it? Thanks!

My first guess is a carb jet is plugged. You probably know this but for the benefit; motorcycle carbs work on throttle postion not rpm. It starts and idles so the pilot jet is OK. Cutting out somewhere between 1/4 - 1/2 throttle that would be the needle jet. 3/4 - full would be the main jet. Anyway take the carb apart and the jets out. Use carb cleaner or brake cleaner and blow through all the jets and passages. Inspect the slide rubber diaphragm for holes. Be sure the vent lines are clear. Would be a good time to do the .22 mod if you haven't done it.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 06-07-2012 at 08:06 PM.
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post #3 of 8 Old 06-07-2012, 10:15 PM Thread Starter
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Thanks for info! I was hoping to avoid pulling the carb out but maybe not so lucky. Concerning the .22 mod....will I need to modify the exhaust as well?
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post #4 of 8 Old 06-07-2012, 10:22 PM
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Thanks for info! I was hoping to avoid pulling the carb out but maybe not so lucky. Concerning the .22 mod....will I need to modify the exhaust as well?
The .22 mod is just for the carb. Info here

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #5 of 8 Old 06-07-2012, 10:30 PM
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Did the .22 mod, pulled snorkle, installed UNI filter, no exhaust mod worked well on my 09.
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post #6 of 8 Old 06-08-2012, 06:42 AM
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My first guess is a carb jet is plugged. You probably know this but for the benefit; motorcycle carbs work on throttle postion not rpm. It starts and idles so the pilot jet is OK. Cutting out somewhere between 1/4 - 1/2 throttle that would be the needle jet. 3/4 - full would be the main jet. Anyway take the carb apart and the jets out. Use carb cleaner or brake cleaner and blow through all the jets and passages. Inspect the slide rubber diaphragm for holes. Be sure the vent lines are clear. Would be a good time to do the .22 mod if you haven't done it.
Ray Bradbury just died, and . . . Rod Serling's been gone a while.

Still, there seems something like "The Twilight Zone" about this thread . . . I don't know, maybe deja vu, all over again . . .

Regardless, agree with the putative diagnosis and treatment.

===========================

Ah, yes!

http://www.klrforum.com/showthread.php?t=8419&page=2

And, great minds run in the same channels, or . . . perhaps there's an ECHO in here!

Last edited by LoneRider; 06-08-2012 at 06:45 AM.
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post #7 of 8 Old 06-08-2012, 01:06 PM Thread Starter
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yes....sorry about the repeat. I'm new here and I could not seem to find my original post so I became a member and reposted elsewhere. Thanks again for the info. I guess I will be doing some carb work this weekend.
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post #8 of 8 Old 09-18-2014, 10:36 PM
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Well...after one Boulder Beer Chocolate Stout, there is no flow through the petock.
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