Little help please - 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 16 Old 03-15-2016, 07:48 PM Thread Starter
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Little help please

2008 KLR. Out riding today and it sounded like it was missing as I rode it got worse. It starts idles and revs just fine but when you are riding and give it gas to speed up it will surge like it is running out of gas. If you ease it along it will gain speed. It never quit rode it home and put in a new plug no change. What do you think?

Tom
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post #2 of 16 Old 03-15-2016, 08:07 PM
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How long was it sitting before you rode?
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post #3 of 16 Old 03-15-2016, 08:18 PM
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Fuel delivery issue?

I'd check vacuum-actuated petcock operation, fuel lines and carb passages.
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post #4 of 16 Old 03-15-2016, 08:18 PM Thread Starter
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1 day. Rode Sunday afternoon. Got gas and then rode about 20 miles no problems. Rode about 5 or 6 miles today before it started acting up.
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post #5 of 16 Old 03-15-2016, 08:31 PM Thread Starter
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When I pulled the tank to install the new plug I opened the fuel valve and nothing came out. I pulled the valve and it was not stopped up. But when I would move the tank it was almost full of gas I could hear it whistle venting through the gas cap. What should I check?
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post #6 of 16 Old 03-15-2016, 09:38 PM
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Quote:
Originally Posted by tntom View Post
When I pulled the tank to install the new plug I opened the fuel valve and nothing came out. I pulled the valve and it was not stopped up. But when I would move the tank it was almost full of gas I could hear it whistle venting through the gas cap. What should I check?
It's a vacuum operated petcock, fuel wont flow unless you apply a vacuum to it (like cranking the motor over).

Maybe you got some crud in that last tank of gas that partially plugged the high speed jet? Also, check to make sure that the small vacuum line on the petcock is on all the way and not cracked/ leaking vacuum.
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post #7 of 16 Old 03-15-2016, 10:41 PM
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Glad ya caught it early.

The problem is going to be small so please be patient with all there is
to go over. Tiny split in the crappy (quick to dryrot) vac lines, piece of crud as
Stew and Damocles alluded to, sticking tank vent? My '09 has had most of the
rubber replaced by now and your bike is that age too. You'll see cracked rubber
behind the headlight boots, stuff that isn't even exposed. The octopus can be
affected by leaks too. After replacing hoses started to get annoying, I removed
and capped the entire vac system.

It's a great bike and that's why we all own one. The rubber and factory grease are
weak points other than the doohickey which usually gets the spotlight. The rubber
started falling apart on mine in two years. The boot over the ignition, everything.

A few feet of fuel line will redo all the vac and gas tubes, and leave extra for a T mod.

My way was a 9 inch fuel line, period, done.

This is my son, with whom I am well pleased." ----God
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post #8 of 16 Old 03-16-2016, 05:53 AM Thread Starter
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Originally Posted by CheapBassTurd View Post
Glad ya caught it early.

The problem is going to be small so please be patient with all there is
to go over. Tiny split in the crappy (quick to dryrot) vac lines, piece of crud as
Stew and Damocles alluded to, sticking tank vent? My '09 has had most of the
rubber replaced by now and your bike is that age too. You'll see cracked rubber
behind the headlight boots, stuff that isn't even exposed. The octopus can be
affected by leaks too. After replacing hoses started to get annoying, I removed
and capped the entire vac system.

It's a great bike and that's why we all own one. The rubber and factory grease are
weak points other than the doohickey which usually gets the spotlight. The rubber
started falling apart on mine in two years. The boot over the ignition, everything.

A few feet of fuel line will redo all the vac and gas tubes, and leave extra for a T mod.

My way was a 9 inch fuel line, period, done.

Did you replace the petcock?
What is a T mod?
The tank vent under the seat. Is there some kind of check valve in the tank on it?
Sorry to sound dumb but this is my first KLR.
And you are right the rubber is going bad on a lot of stuff. The fuel lines looked ok but I didn't look that good. I will replace the fuel and the vac line first.

Thanks
Tom
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post #9 of 16 Old 03-16-2016, 08:11 AM
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Before replacing any lines, you might check to see if they are free-flowing first.

Turn petcock on, apply vacuum to carb port line, see if fuel flows freely from tank.

With carb connected, open petcock and vacuum applied, open carb drain screw and see if carb discharges fuel.

If no or insufficient fuel flow in either case, see if open filler cap makes a difference.

BTW: The Tee mod involves placing a tee fitting in the carburetor breather hose, and routing an auxiliary hose to a protected higher elevation, providing an alternate path for atmospheric pressure to the surface of float bowl fuel. A Generation 1 stock KLR650 will flame-out in a water crossing of 10" or greater depth without this mod.
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post #10 of 16 Old 03-16-2016, 10:03 AM
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Damocles covered it.

There are aftermarket non vacuum fuel valves (petcock) but I holed the diaphram
in the stock unit and put it back on with the back nipple capped off.

That was to eliminate breakdown causes, along with bypassing safety switches.

This is my son, with whom I am well pleased." ----God
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