Last half of the tank issue - Page 2 - 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 #11 of 36 Old 03-31-2020, 05:55 PM
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....you can always just open the tank when it happens to see if the problem goes away....


Dave
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post #12 of 36 Old 04-08-2020, 08:57 PM Thread Starter
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Originally Posted by DPelletier View Post
....you can always just open the tank when it happens to see if the problem goes away....


Dave
I put a couple hundred miles on the bike today and had the issue again. Here's the scenario:

After running down a tank with no issue, I filled up and continued my ride. About 60 miles into the tank, I started having the engine sputter. Driving at 60, level road, the bike would run. Ask anything more of it; pull a hill, pass, anything that required getting on the throttle and the bike would object. Sputter severely, even buck a bit. But it would never die.

Stopped and checked if there was fuel in the filter, yes. Opened up the gas cap, started the bike and drove with the cap cracked open. No change in symptoms within 4 miles, so I shut the cap again.

Kept riding and about 20 minutes later, it suddenly clears up and rides fine the 60+ miles home.
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post #13 of 36 Old 04-08-2020, 10:06 PM
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The smallest particle clogging the carb can also cause these symptoms.

You just proved that it has nothing to do with half a tank. You refilled and it did it 60 miles later and then persisted with the cap open.

You don't have a fuel flow or tank issue.

Unless I'm missing something here.
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post #14 of 36 Old 04-08-2020, 11:04 PM Thread Starter
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The smallest particle clogging the carb can also cause these symptoms.

You just proved that it has nothing to do with half a tank. You refilled and it did it 60 miles later and then persisted with the cap open.

You don't have a fuel flow or tank issue.

Unless I'm missing something here.
Agreed. But I feel like I'm missing something. Debris being intermittent is something I can't put a finger on. I have had the carb off twice. Once when I purchased as it had sat long enough to not idle and jets were mucky. 2nd time was to do a KLX needle install. It's been cleaned decently. Note, I didn't break it down completely. I've shot air through...but again, it's the intermittent that's getting me.
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post #15 of 36 Old 04-09-2020, 09:49 AM
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Agreed. But I feel like I'm missing something. Debris being intermittent is something I can't put a finger on. I have had the carb off twice. Once when I purchased as it had sat long enough to not idle and jets were mucky. 2nd time was to do a KLX needle install. It's been cleaned decently. Note, I didn't break it down completely. I've shot air through...but again, it's the intermittent that's getting me.
Have you considered draining the float bowl thru a clean, clear battery vent hose into a clean glass jar to look for possible crumbs/floaties from the bowl? Then turn the fuel on or crank it to flush the bowl some more?

Is your bike a California model with 2 nipples on the back of the fuel tank & a charcoal can opposite the muffler?
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post #16 of 36 Old 04-09-2020, 10:10 AM
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There was an old adage among the British bike riders that went something like this: Ninety percent of all carburetor problems are electrical.

Is your bike an '08 model by chance? The '08s were notorious for wiring rub-through problems that sometimes acted like carburetor issues.

Try removing the gas tank, hooking up an auxiliary fuel supply and starting the engine. With the engine running, grasp the wiring harness on the forward right side and wiggle it in an effort to replicate the conundrum. Repeat this procedure by wiggling the wiring harness in various locations. If the symptoms show up during this process, you've found the problem.

Jason
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post #17 of 36 Old 04-09-2020, 10:28 AM Thread Starter
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[/quote]
Have you considered draining the float bowl thru a clean, clear battery vent hose into a clean glass jar to look for possible crumbs/floaties from the bowl? Then turn the fuel on or crank it to flush the bowl some more?

Is your bike a California model with 2 nipples on the back of the fuel tank & a charcoal can opposite the muffler?[/QUOTE]

It is not a cali bike. I've checked the float height and didn't see any debris running through, but it's an easy check, so I'll run some fuel through and see what I get from the bowl. Front side of my filter looks clean though.
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post #18 of 36 Old 04-09-2020, 10:30 AM Thread Starter
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Quote:
Originally Posted by Norton 850 View Post
There was an old adage among the British bike riders that went something like this: Ninety percent of all carburetor problems are electrical.

Is your bike an '08 model by chance? The '08s were notorious for wiring rub-through problems that sometimes acted like carburetor issues.

Try removing the gas tank, hooking up an auxiliary fuel supply and starting the engine. With the engine running, grasp the wiring harness on the forward right side and wiggle it in an effort to replicate the conundrum. Repeat this procedure by wiggling the wiring harness in various locations. If the symptoms show up during this process, you've found the problem.

Jason
Absolutely worth a try. I've got rain in my forecast through the weekend, so great time to wrench. Thanks for the suggestion.
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post #19 of 36 Old 04-09-2020, 02:32 PM
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I agree with Jason; you've eliminated the gas tank vent as the culprit and since the condition pre-dated your carb work and jetting change it sounds more and more likely that you may have an intermittent electrical problem. Good luck,

Dave
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post #20 of 36 Old 04-09-2020, 04:19 PM
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My '06 would buck and jump on occasion during steady throttle. After lots of cursing, incantations, work...I found that the "choke" cable was not adjusted properly...I had installed Moose Racing handguards, and umm...kinda kinked it a bit...DOH!

Last edited by ymracing; 04-09-2020 at 04:24 PM.
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