Kawasaki KLR 650 Forum - Reply to Topic
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

Thread: KLR650 Starting Issues and Blowing Smoke Reply to Thread
Title:
Message:
Trackback:
Send Trackbacks to (Separate multiple URLs with spaces) :
Post Icons
You may choose an icon for your message from the following list:
 

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










  Additional Options
Miscellaneous Options

  Topic Review (Newest First)
02-21-2020 08:20 PM
pdwestman An engine will Run on 100% Berryman B-12 Fuel system, Carburetor, Fuel Injection Cleaner. But I have no Idea of what its MON might be.

I ensure that Fresh Non-Ethanol gasoline is feeding in right behind it, so its blending. If that can't clean a restricted pilot jet & passage ways in 2 float bowl fulls, then the carb needs to be removed, dis-assembled & properly, completely Cleaned.
02-21-2020 05:47 PM
ymracing
Quote:
Originally Posted by Z-08 View Post
So new update finally! I went ahead and replaced the fuel tap and rebuilt the carburetor. I can now get the bike to start, though I think I fouled the new plug I put in last month. The idle is rough and I still seem to be getting some incomplete combustion. I'm thinking one of my issues might have been mixing too much seafoam into the tank (I probably ended up with a 50/50 mixture when I added a can to maybe a quart of gas). I'm going to go ahead and get a new plug and see what that gets me
1 can treats 16 gallons of fuel. for 1 qt - 1/4 oz.

Surprised it started, and I bet the exhaust had a distinct smell...
02-21-2020 02:47 PM
Z-08 So new update finally! I went ahead and replaced the fuel tap and rebuilt the carburetor. I can now get the bike to start, though I think I fouled the new plug I put in last month. The idle is rough and I still seem to be getting some incomplete combustion. I'm thinking one of my issues might have been mixing too much seafoam into the tank (I probably ended up with a 50/50 mixture when I added a can to maybe a quart of gas). I'm going to go ahead and get a new plug and see what that gets me
01-16-2020 05:01 PM
pdwestman
Quote:
Originally Posted by Z-08 View Post
I believe the bike is running rich since it will only start with the throttle held about 1/4 of the way and the choke/enrichment circuit fully off. When it does start in this condition, thick grey smoke comes out of the exhaust.
What you seem to be describing here is a flooding issue.

The Keihin CVK carburetor does NOT have the brass overflow stand pipe in the float bowl. Therefore any flooding is up the jets into the throat of the carb and down the intake port to the cylinder. Even moderate cases of flooding can put gallons of fuel into the crankcase oil, unless the fuel valve is turned OFF everytime.

Disconnect the fuel hose from the fuel tap and confirm that it does not Dribble or Drip in the off position! Are you using the vacuum automatic fuel tap or a manual fuel tap? If automatic tap, also confirm no drips in the On & Reserve positions.

Extreme cases of flooding can have raw fuel leaking into the air filter box or even worse rising out through the pink float bowl air vent hose.

With the bike vertical on a work stand you can attach a clear tubing to float bowl drain nipple, open the screw and hold tubing up alongside carb body to check operating service fuel level. Should never be more than .5mm above gasket surface.
01-16-2020 11:45 AM
Z-08
Quote:
Originally Posted by My84KLR View Post
Ok Iím pretty sure I found both our problems - especially since you said you took your carb apart. Thereís a collar guide that the needle jet goes into and is known for falling out when you take a carb apart. I just looked at my bike annnddddd itís missing so Iím pretty confident thatís my issue and sounds like itís what happened to yours. I bought my bike with my issue so I know I donít have the piece hiding anywhere.

Reference this thread to see what Iím talking about. Look at posts #18 and #21. Take out your air filter and stick a mirror or put your phone camera on and stick phone in airbox to see if this collar is missing. Iím sourcing to get one asap for my bike tomorrow
I know the exact part you're referring to and it did make it back into the older carburetor when I rebuilt and cleaned it. I haven't taken apart the new carburetor to see if it's missing one. I'm going to try and swap in the old carburetor to see if it will now work in the bike with the replaced nut and new spark plug.
01-16-2020 11:41 AM
Z-08
Quote:
Originally Posted by Chuck B View Post
How are you determining that its running rich? KLR carb does not have a choke but rather a separate enrichment circuit. That circuit is engaged (enabled) when the lever is pulled. You are not supposed to engage the enrichment circuit once the bike is warm and or running....only at first cold start. Engaging the circuit will almost always kill the engine. If your problem is the bike will not run AFTER its warm and when the enrichment circuit is turned off (disabled) then that tells me you have issues with the pilot jet. Not very often the issue is with either the pilot circuit or fuel circuit. Both of them pull fuel thru the pilot jet and both required to idle. As My84klr was stating if you or someone else has gone into the carb since it last ran fine then the item/piece that he is referencing may be missing and will cause similar problems. I keep that jet needle in stock as its often gone missing when owners try and DIY their own carbs.
The carburetor that is currently on the bike I bought new in the box from an OEM distributor and I haven't opened up. I have the old carburetor that was originally in the bike that I'm going to try again (it has been fully cleaned and rebuilt).

I believe the bike is running rich since it will only start with the throttle held about 1/4 of the way and the choke/enrichment circuit fully off. When it does start in this condition, thick grey smoke comes out of the exhaust.
01-14-2020 05:42 PM
pdwestman
Quote:
Originally Posted by My84KLR View Post
As a final update for the OP this collar part did fix my problem! Starts up quick and has super stable idle and no black smoke. Currently have a collar from a zl600 until I get proper one in
It will kind of interesting for you to compare the (1986?) ZL600 needle JET to the KLR needle JET.

Why you might ask?
Because in the service manuals they are both listed as a #6 orifice size. They are different part numbers thou.
So I wonder if one is taller than the other, which does affect the fuel drawn thru them.

I think a taller one would be richer, but not sure.
01-14-2020 04:18 PM
My84KLR As a final update for the OP this collar part did fix my problem! Starts up quick and has super stable idle and no black smoke. Currently have a collar from a zl600 until I get proper one in
01-14-2020 04:16 PM
My84KLR
Quote:
Originally Posted by Chuck B View Post
Quote:
Originally Posted by My84KLR View Post
He said it was blowing black smoke which indicates too much fuel/rich.

The missing part we are talking about that you keep in stock. How much do you charge for one? And is it oem or aftermarket?
Sorry, I don't sell/ship out small parts like this one. I only recommend/use OEM parts when it comes to the KLR carb. I'd suggest Rockymountainatvmc.com They have 6ea OEM pieces in stock. Part # 16017-0055 $29.96.
Thanks - I reached out to a friend and I can get a new oem one for $30 from him so I plan on doing that.
01-12-2020 10:03 PM
Chuck B
Quote:
Originally Posted by My84KLR View Post
He said it was blowing black smoke which indicates too much fuel/rich.

The missing part we are talking about that you keep in stock. How much do you charge for one? And is it oem or aftermarket?
Sorry, I don't sell/ship out small parts like this one. I only recommend/use OEM parts when it comes to the KLR carb. I'd suggest Rockymountainatvmc.com They have 6ea OEM pieces in stock. Part # 16017-0055 $29.96.
This thread has more than 10 replies. Click here to review the whole thread.

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

 
For the best viewing experience please update your browser to Google Chrome