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Discussion Starter · #1 ·
Hello all - excuse the noob in the room, but I’m coming up short in figuring out some issues I’m having on my 2008 KLR with no mechanical upgrades from stock with just over 10k on the engine. I am the third owner of the bike, and am running into issues with the fuel getting to the engine while running at hwy speeds (not a speed racer but keep pace with traffic) and a little idle issue. I have since re-checked all my fuel line connections, bolts that I touched, and fuel tank level. From the outside everything looks fine, but I’m not trusting that the problem won’t come back at all...

A little back story:
I recently installed Tusk frame bars and was having issues with getting the bike to start after I reinstalled the fuel tank. Because of the starting issues I noticed that I was low on oil (changed it and the filter), replaced the spark plug (glad I did that!), and checked the fuel filter (it looks in decent shape, but might change it this weekend). My starting problem was a disconnected hose, but those extras have helped the ride sound smoother and it took away the misfires I was hearing on a frequent basis when I was down shifting before the tusk installation. The bike had been sitting for two weeks as I was out of town prior to the changes.

I ran it last night around the neighborhood to get the the fluids running again and ran out of gas, but flipped it into reserve to get home. I was feeling like it would be a good day to ride to work in sunny so cal with my smooth rider, but I ran into some possible fuel starving issues. Before the ride I filled up the tank and got on my way, not remembering about the reserve switch. At around 5 miles in the ride while riding at 70mph the engine had a glitch and kinda lost powered. As I prepared to pull over, fuel kicked back in and I was back up to speed. I looked down to check my fuel flow switch and noticed it was still in reserve, and flipped it over to the on position. This happened again at about mile 20 but this time the engine shut off completely. Holding the clutch in I pulled over, let it sit for about 2 mins, checked to make sure I wasn’t losing fuel (tank still close to full and no moisture on the engine - anywhere), flipped the bike into the reserve tank just to get it started and off the freeway, and boom it started up. I got back up to 60 mph for another 5 miles to the exit. I got to the 4 stop light and the engine sounded like it was having a struggle with idling, and Then cut out again! I pulled over and switched the fuel into the on position which made it start up easy again. I messed with it a couple times since and drove it for lunch without the engine cutting out, but still if I’m at a stop light for the whole 2 minute red to green Cycle the engine struggles to hold a good idle.

Does anyone have a good suggestion for what to do, or what the problem could be?Should I change the fuel filter and look for anything else?
 

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Discussion Starter · #2 ·
UPDATE:::
While riding home the problem of the engine did not occur. However, for 15 miles i was keeping a 65-68mph at 4000rmp in 5th, and had a couple slight loss of power plus a couple loud back fires. I then got it up to about 72-75mph at 5000rpm and rode the rest of the way like that on the freeway. When I exited to go back roads it seemed like anytime I was in the 3500-4000 rpms I would get slight loss of power and backfires between 2-4th gear.
Any ideas or feedback is greatly appreciated!
 

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You changed your spark plug. I would remove it and inspect if you break the insulation. Backfire is usually related to misfires.
 

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Discussion Starter · #4 ·
You changed your spark plug. I would remove it and inspect if you break the insulation. Backfire is usually related to misfires.
Thanks for that Joe...if I didn’t know what that meant - what would I look for while inspecting the plug for a break of the insulation?
 
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