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Discussion Starter #1 (Edited)
Hi all, I have a 2007 KLR 650 with approximately 6300 miles. A few days a go, I was riding back from Capital Reef in Utah back to Grand Junction when my motor cut off. I was doing approx. 80 mph, and also noticed my speedometer cable came loose and detached. After a few minutes, I was able to reattached the cable, and the moto started and I was on my way. After a few minutes, it died again. This time, no luck getting it restarted and battery eventually done for. Tow service came out, jump started the KLR, rode it for 1 mile at 80 mph, then died...One tow, $350 later, and a late night into the morning arrival to my house, and searching the internet for solutions.

Flashforward 24 hrs...I did "top" the tank off in Green River on the way out to Capital Reef, and died with a half a tank, check the air filter (just a little dirty), replaced the spark plug, took the carb off and cleaned it (it appeared clean, but disassembled almost all except float and use carb cleaner), placed back on moto.

Flashforward 1 hr later, I jumped the moto, let it run at idle for 10 minutes, and thought victory was at hand. All seemed fine until I did my test drive around the block. At first, it seemed a little bumpy thinking it was the road. but, after a minute, it started to feel a little jerky and I was only doing approx 20 mph. After a couple of minutes, I heard a slight backfire just before pulling into my driveway, then I let the moto idle and then it died. Total drive time: approx 2 minutes & 1 mile, and no more than 20 mph.

Need help finding a solution to this problem. Thanks in advance!

Dejan
 

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Hi all, I have a 2007 KLR 650 with approximately 6300 miles. A few days a go, I was riding back from Capital Reef in Utah back to Grand Junction when my motor cut off. I was doing approx. 80 mph, and also noticed my speedometer cable came loose and detached. After a few minutes, I was able to reattached the cable, and the moto started and I was on my way. After a few minutes, it died again. This time, no luck getting it restarted and battery eventually done for. Tow service came out, jump started the KLR, rode it for 1 mile at 80 mph, then died...One tow, $350 later, and a late night into the morning arrival to my house, and searching the internet for solutions.

Flashforward 24 hrs...I did "top" the tank off in Green River on the way out to Capital Reef, and died with a half a tank, check the air filter (just a little dirty), replaced the spark plug, took the carb off and cleaned it (it appeared clean, but disassembled almost all except float and use carb cleaner), placed back on moto.

Flashforward 1 hr later, I jumped the moto, let it run at idle for 10 minutes, and thought victory was at hand. All seemed fine until I did my test drive around the block. At first, it seemed a little bumpy thinking it was the road. but, after a minute, it started to feel a little jerky and I was only doing approx 20 mph. After a couple of minutes, I heard a slight backfire just before pulling into my driveway, then I let the moto idle and then it died. Total drive time: approx 2 minutes & 1 mile, and no more than 20 mph.

Need help finding a solution to this problem. Thanks in advance!

Dejan
I kind of doubt this is it, but it could be and it's easy to check. Your bike can run, cut out, run, cut out if the gas cap isn't venting. Open it up and take a ride. If it still cuts out, that's not it.

I have also found that Seafoam added to the gas can fix many things it shouldn't fix. That stuff is magical.

I doubt the speedo cable is related. Also, the KLR is the easiest bike to push start that I've ever owned. That wouldn't have helped in this case, I guess, but it's a good thing to know if you don't already.

Now, we wait for the smart guys to come and pinpoint exactly what it is, making me look like a maroon. :)
 

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Discussion Starter #3
Ok, so far I have done these on my checklist in narrowing my diagnosis: 1) added a proportionate amount of SeaFoam to my gas tank, 2) ran my moto with gas cap ajar...result: sluggish riding, with increased hesitation, almost to the point of stalling. Came back to my driveway and let moto idle for 5 minutes before it stopped.

:character00201:
 

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Bad Running

I had an old 33 Ford that sat out in a field for ??? before I bought it.

Every time I would drive it around in a sand pit next to my house, it would run rough, and quit. It turned out to be a bunch of mouse nest in the gas tank. If left to sit for a while, the gas would filter through the stuff, and let the engine run ok for a while. After the engine was run for a short time, the nesting material would flow up and block off the fuel line. I drove me crazy until I drained the stuff out of the tank.

Could you have put in some bad gas into the tank, that is blocking the shut off?
Remove the petcock, clean, and check the flow. Try emptying the tank. Look for junk in the gas coming out. Put fresh gas in.
 

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Discussion Starter #7
Ok, so I decided to pull the carb out and do another cleaning and the 0.17 cent mod. My jets were clogged, and did the steel fiber clean out. Carb fluid is now jetting from all pin holes. Carb reassembly is next...
 

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Welcome to the wonderful world of 10 % ethanol fuel.

Ethanol production has a bigger "carbon footprint" than refining petroleum; and--without taxpayer subsidies, is unsustainable in economic production. Negative for the environment, negative for the economy (higher fuel costs), and adds to the national debt (not that anyone notices).

And . . . ethanol clogs carburetors.

WHY ethanol?

[/rant]
 

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Discussion Starter #9
Cleaned jets...were a little dirty. Road test: same thing...2 minutes of run time, hesitation, then a small backfire, engine then dies. Next...petock & fuel pump...
 

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This is a long shot but try taking off your gas tank and flushing it out. Drain it by turning it upside down. KLR gas tank bottoms can hold pockets of water.
 

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I had/caused the problems OP had. I installed front crash bars, had to take tank off and when installing tank, didn't like the short hose/back vac hose and put longer thinner one on. Well it kinked unbenowenced to me. went for ride, down highway with wind, no problem, on way back against wind, bike kept dyeing but would restart. Found the kink, got right hose, and again little longer, put hose clamps on, had kinda the same issue , so did a full pet-cock vac delete, and all has been well. Till I put the paniers on then cause my other problem that required a new neutral switch and deleted kickstand and clutch safeties. Just recent is the humidity hear in southern TX, lots of it, heavy dew every morning, so must have had/get water in fuel, so need to add dry gas at every fill up.
Lots of great and knowlegeble people hear, that helped me fix my mess ups. Check out the one I posted, orange oil coming from back of bike.
 
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