So I took the fuel tank off... - Kawasaki KLR 650 Forum
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post #1 of 36 Old 11-04-2012, 09:00 AM Thread Starter
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So I took the fuel tank off...

I took the tank off to run a powerlet cable, put everything back together and the bike ran fine for 3 miles. Then it died when I came to a stop. I can get it to restart with no choke and the throttle held wide open, barely, but it won't stay running, it sounds awful and is blowing smoke out of the exhaust. It definitely smells flooded as well after restart attempts.
It is an an 09 with 960 miles, not even out of its break-in yet.
I am sure it is related to the tank removal, so what could it be?
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post #2 of 36 Old 11-04-2012, 09:10 AM Thread Starter
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Doing some research, could the vent line for the carb be pinched? Would that cause it?
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post #3 of 36 Old 11-04-2012, 09:33 AM
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I doubt it's your vent line pinched... I suspect that you missed hooking up the little vacuum line that runs to the petcock? It's small and kind of tucked in behind so it's hard to see, and easily forgotten!

Edit: That wouldn't explain it sounding flooded though... It just wouldn't be getting any gas.

Perhaps the vent line did get pinched when you put the seat back on? I would take the seat off and check it out... It has to be something simple!


Last edited by 650Stew; 11-04-2012 at 09:41 AM.
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post #4 of 36 Old 11-04-2012, 09:47 AM Thread Starter
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Nope I got it back on the petcock but I may have torn it, or it could have gotten pulled off the carb side. I will definitely look into the vacuum hose being the culprit though, especially if you think it may explain the symptoms!
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post #5 of 36 Old 11-04-2012, 09:53 AM
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Originally Posted by longroute View Post
Nope I got it back on the petcock but I may have torn it, or it could have gotten pulled off the carb side. I will definitely look into the vacuum hose being the culprit though, especially if you think it may explain the symptoms!
It's quite common for people to forget to reconnect that vacuum hose, that doesn't explain it sounding flooded though... If it was a problem with the vacuum hose you just wouldn't be getting any gas. I didn't read your initial post closely enough before I replied, when I saw you had the tank off and it dying 3 miles later I immediately thought of the hose being off.

If your bike is flooding though, it has to be something else. My apologies for my misdiagnosis, I think I got up too early this morning .

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post #6 of 36 Old 11-04-2012, 12:19 PM Thread Starter
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Thanks a lot for getting my hopes up that it was something simple
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post #7 of 36 Old 11-04-2012, 12:49 PM
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Thanks a lot for getting my hopes up that it was something simple

Lol! I'm sure it is something simple, all you did was take off the tank

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post #8 of 36 Old 11-04-2012, 01:09 PM
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I think what you did was...when you lifted the tank off you pulled the choke cable and it has been stuck in the full choke position. Take the tank off again and see on the lefthand side if the choke is sitting completely inside it's little fitting. You will need to pull back the rubber boot a bit. I also bet you have probably broken the little tabs that hold the cable in place so you should go out and buy the metal replacement to stop that from ever happening again. It's a mod any way so you just killed two birds with one stone.
If you did pull the cable, just push it back in to where it wants to live and try again. Now get some zip ties and clean up the wiring so it's tight to the frame and also zip tie that choke cable but not so tight that it may cause it to hang up and hold the choke on a bit.....it will ruin your engine over time if the bike is constantly getting way too much fuel. That is IF you keep riding it that way.
You can also tie the throttle cables back a bit too....not tight but just enough so you don't pull them next time when you take the tank off.


IF, you haven't already done the pilot screw plug removal now it a good time to do it, imho. Set the pilot screw to 2 turns out from seatd.....look it up in the how to section.

Hope this helps......

Willys
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post #9 of 36 Old 11-04-2012, 02:11 PM Thread Starter
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That makes sense, since it was really cold out when I started the ride, i was able to get a couple of miles before it warmed up enough. Hopefully I get a chance soon to check. Losing an hour of daylight is not helping my chances though. I'll let you know, thanks!
Another thing I learned is that when hitch-hiking home, your chances of getting picked up are greatly increased if you carry your helmet with you...
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post #10 of 36 Old 11-04-2012, 03:49 PM
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Yup, what Willy's is saying makes a lot more sense and would explain the flooding as well. Hopefully you can get it fixed soon

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