'05 KLR sputters out after a short riding time - 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 11 Old 11-06-2019, 08:33 PM Thread Starter
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'05 KLR sputters out after a short riding time

Hey guys,

I bought an '05 KLR about six months ago for a decent price, the previous owner said it idled weird but other than that, it was a good bike. I took it for a test ride and let it idle for more than 20 minutes. The idle sped up but the bike stayed on and kept running, Being new to motos I took it in to have it looked at and my local shop worked on the carb and fixed the idle. After that it idled perfect and I took it home. THEN I took it out for a ride that day. Ran great for 45 minutes ish, then began to sputter and died. It would run for another minute and the same thing would happen, continuously. Took it in again, so what they've done is new petcock, carb work and a once over. Again, the bike runs for 30 minutes and begins to sputter and shut off, followed by shutting off after every 30-60 seconds. I bought a new 2018 KLR, that obviously is my daily bike now, but I would love input so I can try to fix the older bike myself. Electrical? fuel issue? Im too inexperienced to know so looking for advice. I have the stock tank as well as a bigger 6 gallon desert tank if that helps. Thank you. -Cole
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post #2 of 11 Old 11-06-2019, 09:20 PM
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When you say carb work ... do you mean they rebuilt it? New gaskets? New diaphragm? Cleaned all the jets and passages? It they just adjusted idle and/enrichener?

Did you also pop the gas cap to check for a vacuum? It can happen. If you have a vacuum petcock, that too has a vaccine line and if it is pinched or has a hole the fuel will not flow.


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post #3 of 11 Old 11-07-2019, 09:56 AM
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I kinked my/1 of my vacume lines after installing the front crash bars. It ran fine on a 50 mile trip with the wind, and died out 4 times on the way back against the wind.
With help from hear, I found the half bent vac line, and all was well after I unkinked it. BUT, soon after did a pet-cock vac delete.
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post #4 of 11 Old 11-07-2019, 10:44 AM
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my first thought was tank vacuum as well. The next time it does it, open the cap and see if the problem goes away.

Dave
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post #5 of 11 Old 11-08-2019, 03:34 PM
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Not to hijack, but having similar issues. Figured it fit best here.

On my 2000k mile run recently, I noticed some intermittent hesitation/decel while at steady throttle. Pitch of the engine doesn't change. Only seems to happen after riding a bit. Couple days ago, heard some popping on decel. Not crazy, but there. Before the popping, I assumed it was a fuel delivery issue and changed stock petcock to EM. Tank vent checked and new fuel line isn't kinked. So diaphragm first?

Guessing I'm after a carb rebuild with diaphragm? Have seriously considered a KLX kit, but I'm not power hungry on this bike. I dig the range 45-50 mpg gets me.

Sounds like a lawnmower, Rides like a paint shaker!

I got 99 problems but fuel injection, 6th gear or a 2nd cylinder ain't 1!

My wife: "I didn't know if that was you coming home, or a neighbor mowing"
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post #6 of 11 Old 11-08-2019, 05:09 PM
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Originally Posted by Sportinh2o View Post
Not to hijack, but having similar issues. Figured it fit best here.

On my 2000k mile run recently, I noticed some intermittent hesitation/decel while at steady throttle. Pitch of the engine doesn't change. Only seems to happen after riding a bit. Couple days ago, heard some popping on decel. Not crazy, but there. Before the popping, I assumed it was a fuel delivery issue and changed stock petcock to EM. Tank vent checked and new fuel line isn't kinked. So diaphragm first?

Guessing I'm after a carb rebuild with diaphragm? Have seriously considered a KLX kit, but I'm not power hungry on this bike. I dig the range 45-50 mpg gets me.
Coasting enricher?

On another note, while stock is fine, I'd suggest that better mileage gained by running the bike overly lean (like the stock set-up) isn't a good way to increase mileage.

2 cents,
Dave
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post #7 of 11 Old 11-08-2019, 05:41 PM
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Originally Posted by DPelletier View Post
On another note, while stock is fine, I'd suggest that better mileage gained by running the bike overly lean (like the stock set-up) isn't a good way to increase mileage.

Yep. I believe thatís why it pops when he decelerates. If I recall what Iíve read her and experienced elsewhere a lean condition can case popping like this.


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post #8 of 11 Old 11-08-2019, 09:09 PM
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Quote:
Originally Posted by Sportinh2o View Post
Not to hijack, but having similar issues. Figured it fit best here.

On my 2000k mile run recently, I noticed some intermittent hesitation/decel while at steady throttle. Pitch of the engine doesn't change. Only seems to happen after riding a bit. Couple days ago, heard some popping on decel. Not crazy, but there. Before the popping, I assumed it was a fuel delivery issue and changed stock petcock to EM. Tank vent checked and new fuel line isn't kinked. So diaphragm first?

Guessing I'm after a carb rebuild with diaphragm? Have seriously considered a KLX kit, but I'm not power hungry on this bike. I dig the range 45-50 mpg gets me.
Any aftermarket muffler can not Muffle the trailing throttle after-fire as well as the oem muffler will.

A loose exhaust header pipe or damaged header pipe gasket or crack in the header pipe will cause more & louder after-fire / popping.

A rotted/damaged/sticking idle air cut-off diaphragm will cause more & louder after-fire / popping.

The 22 cent mid-range needle shim mod or the KLX mid-range needle may alleviate your mid-range steady throttle intermittent hesitation.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #9 of 11 Old 11-08-2019, 10:52 PM
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Quote:
Originally Posted by pdwestman View Post
Quote:
Originally Posted by Sportinh2o View Post

Guessing I'm after a carb rebuild with diaphragm? Have seriously considered a KLX kit, but I'm not power hungry on this bike. I dig the range 45-50 mpg gets me.
Any aftermarket muffler can not Muffle the trailing throttle after-fire as well as the oem muffler will.

A loose exhaust header pipe or damaged header pipe gasket or crack in the header pipe will cause more & louder after-fire / popping.

A rotted/damaged/sticking idle air cut-off diaphragm will cause more & louder after-fire / popping.

The 22 cent mid-range needle shim mod or the KLX mid-range needle may alleviate your mid-range steady throttle intermittent hesitation.
So I've kept bike stock in the exhaust / carb department, because I enjoy the distance (mileage) the stock setup gets me, but I understand what you're saying. I'll look over the exhaust side.

I'll give the carb an inspection. It's a new symptom and it seems a bit progressive.

Coasting enrichner. I'll have to research.

Sounds like a lawnmower, Rides like a paint shaker!

I got 99 problems but fuel injection, 6th gear or a 2nd cylinder ain't 1!

My wife: "I didn't know if that was you coming home, or a neighbor mowing"
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post #10 of 11 Old 11-12-2019, 10:59 AM
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Originally Posted by ILove2Ride2Wheels View Post
Yep. I believe thatís why it pops when he decelerates. If I recall what Iíve read her and experienced elsewhere a lean condition can case popping like this.


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remember that all Gen2's have an AIS system that produces decel pops by design. The stock silencer muffles them better than the aftermarket units.

Dave
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