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Discussion Starter #1
Been on the road from States for last 10 months. In Santiago, Chile now. Bike needed lot of maintenance so I took it to my friends shop and did lot of work on it in last few days. After putting it back together last night, I started it and it worked fine. Didn't ride it. This morning I tried to start it and carburetor started leaking on the out gas line. Non stop until I closed petcock. I managed to start it and take it for short ride but it kept sputtering and dying and it sounded horrible. I did nothing on carburetor past few days and it worked great before. Closest I got to carburetor was doing valve clearance. Later today I took carb off and cleaned everything. Petcock too. Put it back on, no leak but bike barely starts and keeps dying. Really strange and not sure what to look into now. I took it off again and installed carb from my friends klr but it was late and couldn't start the bike because of neighbors so I'll try in the morning. Only thing that was done in the meantime from last night when it worked fine and this morning is that my friend welded my kickstand with the kickstand on the bike and battery connected. Not sure if that could have mess something up!? I replaced my computer with one from his bike today and problem was still there. Any suggestion?
 

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The leakage likely was from poor float valve seal, perhaps a bit of dirt compromising float valve seating, rectified by your cleaning.

If bike runs with substitute carb, you've gotten a real heads-up on where to start.

I assume you disassembled the carb fully, cleaning all jets before re-assembly, float height correct, and no punctured float.

Recommend you check your diaphragm for proper sealing and any tears or holes; easy to get an air leak if the diaphragm isn't totally snugged in its groove around the carburetor mixture chamber circumference. Diaphragm air leak results in fuel-lean mixture at open throttle.

With suction on petcock vacuum hose, assume petcock opens. Assume "choke" (starting enricher) connected properly and functioning.

Assume spark; good spark plug and high-voltage wiring.

Sometimes, starting fluid can be your friend; will it start and run on starting fluid (have fire extinguisher handy)? If so, but not on gasoline, fuel system/carburetor problem likely.

Recommend jumping with a known hot battery (e.g., from automobile) and cranking with different choke/throttle configurations; even . . . with starting fluid, for diagnostic purposes.

I can't imagine how welding on the chassis or anything connected could cause a problem with starting; probably coincidental only, IMHO.
 

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^^

If it was leaking fuel from the carb, it's pretty likely your float needle is bad or just gunked up. And if it was gunked up your jets likely are, too.
 

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Discussion Starter #4
After installing carb from my friends bike, still same problem. Installed his tank, same problem. Installed his spark plug, bike works fine. Put bike together with all my parts and his spark plug, works fine. Looks like what happened is that spark plug got fried when my friend did welding yesterday morning. For anyone reading this, don't make same mistake like I did with welding. If you do and have problems with bike, check electronics and spark plug first.
 

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Installed his spark plug, bike works fine. Put bike together with all my parts and his spark plug, works fine. Looks like what happened is that spark plug got fried when my friend did welding yesterday morning. For anyone reading this, don't make same mistake like I did with welding. If you do and have problems with bike, check electronics and spark plug first.
Glad your bikes is running; still . . . can't visualize the mechanism whereby welding on your kickstand would fry your spark plug! ;)

Still, I take a little credit, from my post above:
Assume spark; good spark plug and high-voltage wiring.
Apparently, a good spark plug solved your problem. Congratulations!
 

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ive seen welding fry computers and coils but ive never seen a plug go bad that way ..though it is possible it was cracked after installing it just decided to let go then ..ive seen new plugs be bad as well ..
 

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You have to wonder if the flooding carburetor didn't allow enough soot to deposit on the plug to cause it to misfire. It would be interesting to clean the plug and try it again.
 
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