Last half of the tank issue - Page 4 - 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 #31 of 36 Old 04-20-2020, 05:30 PM
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Quote:
Originally Posted by Sportinh2o View Post
So the wife and I were treated to a beautiful hill country ride today. Close to 200 miles in all. Things were actually incredible at the beginning. Best this bike has ever run. 2 up pulling hills at 70+ with more authority than I've experienced on this KLR. Then I fueled up...and it was over almost immediately. After that she was sputtery at worst, boggy at best. I checked to see if umbrella seals were sticking - nope. Same ride with the fuel lid cracked open. Shut the petcock and ran it out of fuel to see what would happen..nothing.

So, after an advanced search on here, I haven't really found what I'm after. What exactly happens when you overfill? I see the symptoms are sputtering, which I definitely have. I don't fill the tank to the tip of the neck...but if you are leaning in the corners on a full tank, I've got to assume this is a distinct possibility.
Well, I'm out of suggestions as to what the problem may be. What happens when you crack open the gas cap?

Perhaps you have an obstruction in the vent tube that comes off the back of the gas tank? You should be able to blow through the end of this tube and with the gas cap open, you should hear air rushing inside the tank.

Perhaps someone will offer a more cerebral solution.

Jason
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post #32 of 36 Old 04-20-2020, 06:36 PM Thread Starter
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Location: TX Hill Country
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Thanks Norton. The gas cap open didn't do anything other that elicit strong objection from the wife, the bike sputtered either open or closed. I'll be pulling the seat after dinner to see what I can see.

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 #33 of 36 Old 04-20-2020, 07:41 PM Thread Starter
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The vent tube off the back of the tank is good, just checked. And the carb vent isn't obstructed or pinched; a vacuum pulls fuel and you can't blow into it.

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 #34 of 36 Old 04-20-2020, 08:20 PM
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Does your bike have the California evaporation crap on it? Could the charcoal canister be full and fuel logged? Have you followed all the vent lines to make sure one hasnít melted shut? How about the capped line that comes out at the bottom of the frame, have you drained it? Iím sure your air cleaner is clean and the filter basket is in the filter.

Hope you get it figured out.
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post #35 of 36 Old 04-20-2020, 08:45 PM Thread Starter
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Originally Posted by Uncle Dick View Post
Does your bike have the California evaporation crap on it? Could the charcoal canister be full and fuel logged? Have you followed all the vent lines to make sure one hasn’t melted shut? How about the capped line that comes out at the bottom of the frame, have you drained it? I’m sure your air cleaner is clean and the filter basket is in the filter.

Hope you get it figured out.
Thanks! It's not a California model. And I just checked the plugged drain line (good thought). It was good. Just sitting here with my Clymer manual, going through it.

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 #36 of 36 Old 05-16-2020, 01:09 AM Thread Starter
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Hey gang, I wanted to take a moment and say thanks for all that have chimed in on this thread. Just an update, share some more info and a bit of rambling.

I haven't experienced the issue in the last 500 miles. A lot has happened to this bike in the last few weeks. I've watched it crash in my mirror (the dust cloud, not the carnage) with brother in law at the helm and took a couple of weeks to put it back together. The BIL is quite fine. Scrapes and bruises as he was mostly protected with gear, but I did figure out he high-sided at 35-40mph. Other than tearing the bike down to the frame and going over pretty much everything, I bought parts and got her back together with relative ease. Since I had her so bare, I went ahead and checked the valves. 3 of 4 at the last thousandth of spec, and one exhaust a thousandth out of spec. 4 new shims in and went ahead with the MC mod too.

The other thing I did was replace the spark plug. I could tell it had been hot previously. I put it in there when I first bought her, about 6k miles ago, so well before the KLX needle. Guessing she ran too lean for some time. Old and new plug being iridium.

Anyhow, I can't definitively say what fixed or even if it's truly fixed, but I haven't experienced the issue since I've put her back together - I have not touched the carb. My hunch is spark, my replacement was just to eliminate that piece of the puzzle.

Heeding Nortons previous advice, I've also tidied wiring. Checked routing, loomed auxiliary power supplies and checked for trouble spots again since the bike went down.

Trip since I put her back together:

I hauled butt to catch my dad's 84th birthday and went across Texas quickly. Steady 75-80 and touched 90+ a few times while out in bfe. Didn't know it would do those speeds without an overwhelming assist of gravity, but she's running really well, so I figured I'll see what she will do. Full panniers, top box- not loaded heavy but it was all catching substantial wind. Ran like a champ but I got 36mpg on that leg but most importantly, made it in time for dinner!

Just to see, on the trip home for 250ish miles, I didn't let her bust 4k rpm. 42.57mpg. 6.5 mpg sacrifice for hauling butt.

I hit 50mpg regularly before KLX mod, with mid 50's if I kept the rpm low as above. Sacrificing potentially 10mpg is something I'm battling internally. I don't want to run lean, and I obviously love the power...no free lunch.

An observation, the MC mod changed the exhaust note a bit. Seems more quiet at low speed. She feels a bit perkier. Before, she would labor to get to 70. Not the case now.

Reason I went for MC mod. Previous to my bikes wreck, I had the opportunity to ride uncle's new to him KLR modded up almost identical to mine except MC mod had been done. Then hop right back on mine. I know no 2 bikes are truly alike, but I did feel a difference. I felt it was worth it to try it on mine. I've certainly witnessed no I'll effects in 500 miles since. And they are definitely more alike in response now. Not claiming a magic bullet here, but hey - it's free and reversible. Next time you have to check valves, might be worth considering.
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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"
Sportinh2o is offline  
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