KLR250 Cutting Out/Dying Issue - Kawasaki KLR 650 Forum
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  • 1 Post By Damocles
  • 1 Post By Dhook0001
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post #1 of 5 Old 03-06-2017, 09:56 AM Thread Starter
Join Date: Mar 2017
Posts: 3
KLR250 Cutting Out/Dying Issue

Hey -
New to the forum and new to a KLR 250. Just picked up the bike Thursday (03/02/2017); finally got it out on the road yesterday. Did a good 20mile ride in the morning; majority on the street. Later met up with some buddies to ride some dirt; rode about another 20mi to get to the location to ride dirt and rode there for about 1.5hrs; jumps/offroad/everything, with no problems.
Heres were it went south we started to head home and a friend got a flat on his bike; so 2 of us took off to the gas station and he an another stayed behind; I knew I was getting low on fuel so I was going to fill up when I got there; about 1/4 mile from the station my bike started cutting out and then completely died. I figured I was out of gas, but could hear some sloshing around. So I tipped my bike on its left side and got all of the gas from the other side of the hump to the petcock. It kicked right over and I was able to make it the rest of the way. I filled up an we took back off to help our friend out; I made it about a mile down the road running about 55-60mph and the bike cut out and eventually died again. I kicked it a few times and it started right back up; this continued about every mile for the next 30miles (my leg was tired hah).
Each time it would die I would flip the petcock back/forth from ON to RES give it a few kicks and it would start up. The bike seemed like it was starving for fuel but it had plenty. I tried to choke it and that would help to keep it idling but it would still die eventually; especially when I came to a stop; the RPMís would just drop to 0 when I pulled the clutch.

This just happened last night; I finally got the bike home at about 9pm (30miles took about 1.5hrs); so I havenít had much time to fiddle around with it but just wanted to get some insights on if this has happened to anyone else and where to look first.
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post #2 of 5 Old 03-06-2017, 10:55 AM
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Join Date: Jan 2011
Posts: 4,490
Last KLR250s were marketed in the US as 2005 models; yours is 13 model years old.

"Dirty" fuel could be the problem; with age, gaskets and fibrous components of the petcock deteriorate; some could have penetrated the carburetor.

I'd recommend a complete carburetor cleaning and adjustment; all you always wanted to know about the KLR carburetor, but were afraid to ask:


My guess regarding your problem: Carburetor/fuel issue. Make sure you have fresh, "dry" gasoline.
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post #3 of 5 Old 03-08-2017, 10:50 AM Thread Starter
Join Date: Mar 2017
Posts: 3
Hey -
Thanks @Damocles; those videos are awesome;
I pulled the tank, petcock, and carb yesterday. The Reserve tube on the petcock was Gone; and Im assuming sucked into the carb tube and carb. Pulled the carb apart and cleaned out the jets, bowl, and everything else. I really didnt find much within the carb its self but plenty in the tube going to the carb; but usually the bits in the actual carb a super small and I was blowing it out with compressed air so who knows if I just blew it out before I could see it. Either way everything is cleaned out. I ordered a new petcock just to be safe so I havent had a chance to restart the bike; petcock should be here later this week I will follow up once I have it completely back together and running I will update.
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post #4 of 5 Old 04-05-2017, 09:37 AM Thread Starter
Join Date: Mar 2017
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Been a few but got this all fixed. Just as I suspected the plastic screen and tube from the petcock that had deteriorated was sucked into the fuel feed tube to the carb and clogged it up. A thorough breakdown and good amount of carb cleaner and everything is all good again.
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post #5 of 5 Old 04-05-2017, 10:26 AM
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Join Date: Jan 2011
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Originally Posted by Dhook0001 View Post
Hey -
Thanks @Damocles; those videos are awesome; . . .
Thank the Producer/Director of the videos, Tom Schmitz, not me, Dhook0001!

Glad you got your KLR250 sorted out; a marvelous and generally under-rated dual-sport.
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