Carb Went Phooey ?? - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 2 Old 11-21-2012, 05:54 PM Thread Starter
2nd Gear
Join Date: Oct 2012
Location: Silver City, NM
Posts: 217
Carb Went Phooey ??

Last week I installed the JD jet kit in my '11 KLR and it screamed. Very pleased with it and put about 50 miles on it. Ran beautifully right up till I shut it down to install the new 6.6 kg rear spring.

When I put it back together I checked the tank vent tube, vacuum tube to tank shut-off valve, gas line, etc., etc.

A while ago I finished it up and being an eternal optimist I put it all back together - fairings and all.

When I went to start it, gave it about choke, which has been about normal, left the twist grip alone and hit the start button. It tried to start, then died out - did that about 6 or 8 times - with it galloping with starter still engaged like it was trying and finally did start, but wasn't very happy about it.

Gave it just a touch of throttle and it died instantly. It finally did start and run for a couple of minutes, then died for good. No feeling that it was even trying to fire, so pulled the fuel line from the tank valve and put an empty bottle over the fitting and cranked it over. Lots of fuel - spurting every time vacuum hit it.

Went around to other side of bike and started to loosen the drain screw at the bottom of the bowl and gas started dripping as soon as I cracked it.

Well, hell.....tore it all down again, pulled the tank off, pulled the spark plug and it was wet. Aha.....flooded....but has never done that before. Dried the plug, plugged it into spark plug lead, held plug against ground and cranked it several revolutions. Stunk pretty bad of gas, but lots of spark at the plug. Cranked it some more to blow the worst of it out of the cylinder, then put plug back in, double checked everything and tried again. It started loping with the starter still engaged, like it was trying to start but not quite making it.

I checked all hoses and tubes for kinks and proper connection, it's got spark and fuel, it was running beautifully when I started this, everything looks to be connected properly........and I'm stuck. What else should I look at ??

When I put the rear spring in, I went too far and separated the rear sub-frame, then realized I didn't need to do that to get at top shock bolt, so put it back together. Looked it over as I was putting it all together and all looked good - nothing broken, pinched or separated - so continued on till I tried to start it.

Help, help.

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post #2 of 2 Old 11-21-2012, 06:32 PM Thread Starter
2nd Gear
Join Date: Oct 2012
Location: Silver City, NM
Posts: 217
Update - left it sitting out there for about hour or so, then tried one more time before dark. Left choke and throttle completely alone. For a few seconds, nothing. Then it started to gallop like it was trying and finally started to run at very low rpm, then died.

Went thru that a couple of times, then gave it about " of choke and it started and ran - lumpy but it was running. Waited a minute or 2, then slowly gave it just a bit more choke and it speeded up. Touch the throttle and it died instantly.

OK, kept increasing choke as it warmed up and got it up to 2,000 rpm, but it was surging - rpm's would increase to about 2300/2400, it would pause and drop back to 1500, then start over. At one point, I very "slooowwwly" opened the throttle and it started to pick up speed, then died.

That's where I'm at now. It'll run - lumpy but running - on the choke. Give it any gas at all from the twist grip and it dies instantly.

Don't know what to think..................Lar.
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