Need help getting KLR to run any help is appreciated. - Kawasaki KLR 650 Forum
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post #1 of 19 Old 04-01-2011, 05:52 PM Thread Starter
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Need help getting KLR to run any help is appreciated.

2001 KLR 650.
I can get it started but it will only idle. The second I apply throttle it dies. I have cleaned the carb, checked the fuel lines, gas level in carb, good gas, petcock, breather tubes, etc,. I cannot figure out why it will not run...

When I do force the throttle and get it to rev, it back fires and the exhaust gets red hot. I cannot back off the choke or it will die.

Any ideas are greatly appreciated! Might it be the valves?

Thank you in advance!!

Al
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post #2 of 19 Old 04-01-2011, 05:59 PM
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awallner -

Some of what you say makes me believe that it is incredibly lean. That makes me think that there is something really wrong on the carb; perhaps it was assembled incorrectly.


Can you give us more background? Is this a new bike to you? Any idea what might have been done to it since it last ran correctly?


There are some bits in the carb that can fall out and roll to the darkest recesses of the work area and never be noticed. It's possible to assemble the carb without them and it all seems fine. Having that happen will wreak all sorts of havoc.


Please, give us some more background and we'll see if we can work through it with you.


T

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Last edited by Tom Schmitz; 04-01-2011 at 06:02 PM.
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post #3 of 19 Old 04-01-2011, 06:08 PM Thread Starter
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Thanks Tom,
It had been sitting all winter and did not run it much last year. When I went to start it up this Spring is when I had the trouble.

Then I took carb off to clean it, was very careful when working on it even laid down white paper on the table. Followed manual etc. Used air to clean out areas with carb cleaner.
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post #4 of 19 Old 04-01-2011, 06:47 PM
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awallner -

Well, let's start at the tank and work our way down.

First off, you should be using good, fresh gas and your air filter should be newly cleaned. Bad gas and clogged air filters cause a lot of issues.

The KLR has a vacuum operated petcock. Both the vacuum line and the petcock can go bad. When that happens the petcock may deliver enough fuel to run at idle, but crap out above that.

To test the petcock, get a length of vacuum hose and stick it on the back of the petcock. Remove the fuel line from the petcock and get something to catch the fuel. Apply a vacuum to it (you should be able to suck on it and open the petcock - I know of know genteel way to say that). If the petcock works, fuel will flow quite copiously. If not, then either the fuel pipes are clogged up or the vacuum bits in the petcock have gone south. If you have a bad petcock I would recommend replacing with a non-gravity operated petcock - see here.

If the petcock does work, then suspect the vacuum line; remove it and inspect/replace it. If it does need replacement, see if the bike works better.

The next item in the chain would be the float level in the bowl. There is a simple test for that using a piece of clear tubing that gets attached to the nipple on the bottom of the carb. See here and subsequent posts for a discussion; Damocles set me straight on this procedure.

If all of the above are good, then you may want to drain the tank of all but a half gallon and give it a good dose of Sea Foam. Let it run on the Sea Foam for a bit and see if it gets better. Since all you can really do at this point is idle, be very mindful of the temperature guage and don't let it overheat.

Let us know what's going on!

T

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“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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Last edited by Tom Schmitz; 04-01-2011 at 07:13 PM.
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post #5 of 19 Old 04-01-2011, 07:02 PM Thread Starter
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Thank you!
This gives me some homework and things to try —*I'll take it easy on sucking on the petcock;-) I'll follow up and let you know the results.

Al
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post #6 of 19 Old 04-01-2011, 07:09 PM
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Welcome to the forum, awallner. You are in good hands. My only suggestion at this point is to follow Tom's guidance, ONE STEP AT A TIME. If we fiddle with eight things, then find the problem went away, we won't know where to look if the problem repeats itself down the road. This method Tom is walking you through should isolate the issue, so you know where to look the next time...

Hopefully there won't be a next time. The biggest part of being lucky is being ready.

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post #7 of 19 Old 04-01-2011, 07:12 PM
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Quote:
Originally Posted by awallner View Post
...I'll take it easy on sucking on the petcock

Watch it buddy - family forum!

See what I mean about no genteel way to say that?

Keep us in the loop.

T

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 04-01-2011 at 07:14 PM.
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post #8 of 19 Old 04-01-2011, 07:12 PM Thread Starter
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Thank you vatrader - I'll take it one step at a time.

Al
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post #9 of 19 Old 04-01-2011, 07:33 PM
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I know you feel you cleaned the carb, but pull the jets out and completely verify that they're clean and that there's no obstructions.. Sounds like your main jet has a little bit of crapola in it...

As the other said one thing at a time, and I always say to start with the simple stuff first.... Pull the bowl and pull the jets..
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post #10 of 19 Old 04-01-2011, 10:31 PM Thread Starter
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Hey guys, first off, I really appreciate all the feedback and help, it is fabulous!

I have gone through all the checks and I am still having the same problem.
I even created Hurricanes' block off gasket option...
Rechecked the jetting and float.
Ran it for some time with the Sea Foam and, even as before, was able to rev it but unable to get it to run consistently — had to keep revving it to keep it running. Still only idles with full choke.

Do you think it could be tight valves?

Again thank you for your feedback and help.

Al
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