Bike won't start after .22mod - Kawasaki KLR 650 Forum
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post #1 of 8 Old 09-16-2012, 02:19 PM Thread Starter
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Bike won't start after .22mod

Hey all,
Did the .22 mod last night and now I can't get the darn thing to start! Has spark, doesn't seem to have fuel. I ran down to reserve before I pulled the tank, tried filling tank from a gas can still no luck... Anyone have any ideas? Frustrated and stuck... Thank you everyone.


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post #2 of 8 Old 09-16-2012, 02:39 PM
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Is your vacuum petcock working ok? I would check that first.

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post #3 of 8 Old 09-16-2012, 03:40 PM Thread Starter
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Not sure yet. In process of going through it... Hoping that it's but will post when I know its not. Thank you for the help. :-) Still interested in everyone else's thought too. Thanks again all!


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post #4 of 8 Old 09-16-2012, 03:49 PM
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Easy enough to see if your float bowl is full or not as well, just loosen that philips (gen 1) screw, or allen screw (gen 2) on the bottom of the carb and see if gas flows out of the overflow... If it doesn't your not getting gas to the carb. Or the float needle is stuck closed, but that's highly unlikely.

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post #5 of 8 Old 09-16-2012, 05:13 PM
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Easy to check petcock; break fuel line, feed into container; apply vacuum (by cranking engine, or by applying vacuum otherwise to petcock vacuum line); fuel should flow freely . . .

Does using "choke" (starting enricher) make any difference? The device is a little "mini-carburetor" all its own, mixing fuel and air; if the petcock's flowing, oughta start!

A most unlikely event, but you may have re-assembled the carburetor incorrectly. Make sure you've an air-tight diaphragm seal, and . . . the slide spring holder/needle assembly's put together the right way.
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post #6 of 8 Old 09-16-2012, 05:30 PM
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On the petcock there are 2 hoses, one for fuel and one for vacuum. Not attaching the vacuum line is the most common mistake as it is hidden in behind and easily forgotten.
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post #7 of 8 Old 09-16-2012, 10:01 PM
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I had the same problem when I did mine. I had forgot to reconnect the vacuum line to the petcock. I would bet that's the likely cause.
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post #8 of 8 Old 09-16-2012, 10:10 PM Thread Starter
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Randy, you are dead on. I checked everything everyone recommended And then decided to just go back in like I was starting from the beginning. Went step by step, and made sure to connect both lines at the petcock, and bam she's back on the road again. :-). Now I just have to figure out how I screwed up the safety switch for the clutch...bike only starts in neutral. Always something, but that's half the fun right!? Thank you everyone for all of your sage advice. I belong to a few forums for different subjects and I gotta say, everyone here is always willing to throw something out there for a fellow rider. I appreciate it.


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