liquid coming from exhaust header - 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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  • 1 Post By pdwestman
  • 2 Post By fearlesspixel
 
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post #1 of 5 Old 07-31-2019, 06:18 PM Thread Starter
1st Gear
 
Join Date: Jul 2018
Posts: 20
liquid coming from exhaust header

Hi all,

So I put a new exhaust on my KLR today, and opened the carb to make sure I had the needle set right for an aftermarket exhaust. When I put everything back together it started right up, after running for a few minutes it died and would not start again. Now I see there is some liquid coming out of the exhaust as you can see in the attached image. I think it's gas because it dripped onto the floor evaporated. Is the bike just extremely flooded? Any recommendations on how to proceed?

Thanks!
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post #2 of 5 Old 08-01-2019, 10:13 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,312
I suspect that is gas, as you do. Do you have the original vacuum operated fuel valve or is it a manual shut-off valve? Hopefully it hasn't filled the crankcase with gasoline over-night?

Is it possible that you had the fuel hose disconnected & some dirt got into the fuel hose and is now jamming the float valve open? Try simply draining the float bowl into a clean glass jar to look for sediment & then turn the fuel valve on or crank the starter to open oem vacuum valve to flush the float valve & bowl.

Might also be good to replace the exhaust header gasket after you get the carb issue sorted out.
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #3 of 5 Old 08-01-2019, 10:49 AM Thread Starter
1st Gear
 
Join Date: Jul 2018
Posts: 20
I was able to get it running this morning, but again it died after about 30 seconds of running. I seemed to want to run if I held the throttle at about 50% while holding the starter button, but would not stay on.

I have the original fuel valve. There were a couple tiny little black specks in the carb gas. The header gasket was completely shot, I just ordered a new one.

I did the Eagle Mike KLX jet kit not long ago, so maybe something came undone. I'm going to pop the carb off for cleaning and I'll double check everything in there, since I have to wait for the new gasket to get here anyway.


Uploaded a picture of the gasket just so you guys can see how bad it was.
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post #4 of 5 Old 08-01-2019, 12:50 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
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Quote:
Originally Posted by fearlesspixel View Post
I was able to get it running this morning, but again it died after about 30 seconds of running. I seemed to want to run if I held the throttle at about 50% while holding the starter button, but would not stay on.

I have the original fuel valve. There were a couple tiny little black specks in the carb gas. The header gasket was completely shot, I just ordered a new one.

I did the Eagle Mike KLX jet kit not long ago, so maybe something came undone. I'm going to pop the carb off for cleaning and I'll double check everything in there, since I have to wait for the new gasket to get here anyway.


Uploaded a picture of the gasket just so you guys can see how bad it was.
Your oem fuel tap may need a new selector disc, # 43049-1017. If the rubber gets torn between the 4 holes the crumb can flow down the fuel hose & jam the float valve open.
Also replace the o-ring on the handle, #92055-1111.

Use a Thin coating of dielectric silicone grease on the rubbers for ease of handle re-assembly.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #5 of 5 Old 08-06-2019, 10:28 AM Thread Starter
1st Gear
 
Join Date: Jul 2018
Posts: 20
Upon tearing the carb apart I found the float valve to be stuck, there was a little piece of a leaf or something in it's socket. After cleaning that out and installing the new header gasket, she's running better than ever! Thanks for the help guys!
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