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Discussion Starter #1
I have an 08 KLR 650. It has about 15,000 miles on it or so. Just last winter I did the valve clearance. It has been ridden very little since then. Now whenever I go to start it it is extremely hard to get it started. It's acting just like it did whenever the valve clearance was near zero. But I know that's not it because that was just taken care of. Once you do get it started it runs fine plenty of power no overheating or anything. I'm thinking it's the crappy ethanol fuel clogged something in the carburetor. I'm really not in the mood to take the carb all the way off mainly because the threads are so messed up on the choke enrichment plastic thing. I was wondering if just taking out the diaphragm and the slide and Blasting some cleaner down through the Jets followed by some compressed air might actually do anything? Or am I stuck with dismantling everything all over again. By the way when I did the valves I also cleaned the carb at that time and everything was fine. The weird thing is the carb was never cleaned for 8 years and it was fine so if that's the problem now I got to wonder what's up. I'm open to any suggestions on what to check.

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If it was my bike I would check the valves again, since hard starting is such a classic symptom. I'd have to have that off the table first.

But you are right, it is probably a carb issue. Lots has changed in the past 10 years with gas. Carbs can now get clogged up in just a few weeks with this ethanol stuff.

There's only one right way to do this, since it is probably the idle circuits that are clogged. Those are tiny and what ethanol causes a problem with. The orifice in the idle jet is only about .014", or the thickness of a few sheets of paper. There are some very fine passage ways that come out just in front of the butterfly, too. The emulsifier has tiny holes, too. You will need to pull the carb to do a proper job. You've done it before, but there are videos on YouTube (a series of four videos) that go through it step by step.

As to the enricher, you might just want to get rid of the plastic ferrule and replace it with a Stead metal ferrule or just go to a carb-mounted enricher.

Stead Engineering Choke Conversion Kit

Son of Stead
 

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You are probably right about the plugged jets in the carb. I had the same problem with mine last year, dosed the hell out of it with SeaFoam. After about 100 miles the bike started and idled fine. Hope it works for you.
 

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Discussion Starter #4
If it was my bike I would check the valves again, since hard starting is such a classic symptom. I'd have to have that off the table first.

But you are right, it is probably a carb issue. Lots has changed in the past 10 years with gas. Carbs can now get clogged up in just a few weeks with this ethanol stuff.

There's only one right way to do this, since it is probably the idle circuits that are clogged. Those are tiny and what ethanol causes a problem with. The orifice in the idle jet is only about .014", or the thickness of a few sheets of paper. There are some very fine passage ways that come out just in front of the butterfly, too. The emulsifier has tiny holes, too. You will need to pull the carb to do a proper job. You've done it before, but there are videos on YouTube (a series of four videos) that go through it step by step.

As to the enricher, you might just want to get rid of the plastic ferrule and replace it with a Stead metal ferrule or just go to a carb-mounted enricher.

Stead Engineering Choke Conversion Kit

Son of Stead
Thanks for the info I can't imagine the valves having a problem in such a short time I was starting to wonder if I did not tighten down something well enough but if something came loose that would increase the clearance I think. Definitely going to look into that choke conversion kit.

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Discussion Starter #5
You are probably right about the plugged jets in the carb. I had the same problem with mine last year, dosed the hell out of it with SeaFoam. After about 100 miles the bike started and idled fine. Hope it works for you.
You put the seafoam in the gas tank I assume correct?

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You put the seafoam in the gas tank I assume correct?

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I put about half a can in a full tank of gas, the bike smoked like hell but it worked. Once I started the bike it would only idle with the choke on. I took the bike out on the highway and got it too high RPM and closed the throttle completely and after repeatedly doing this the idle jet cleared out and she started and idled fine.
 

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The 1st thing that I would do is check the Cold Cranking Compression, with the throttle Wide Open!
Regardless of when the valve tappets were last checked!

Many 2008-2009 units had an over-active KACR. A KLR650 does not start well in a cold climate with less than 80 psi of CCC!

Fresh gasoline starts better than old gasoline. Winter Blend gasoline starts better than Summer blend gasoline in cold conditions.

A 100% clean carb is required, whether the CCC is 80psi or 125 psi. Paying particular attention to the 3 little pilot outlet holes at the Bottom Edge of the throttle plate.

Remove the Phillips screw from the throttle cable bracket before dis-engaging the throttle cables from the carb, remove bracket with cables!
Remove the carburetor air duct clamps Completely.
Push the rear air duct off of the carb with your Left thumb & spiral the carb out of the engine bay with a counter-clockwise rotation. Installation is exactly reversed.
 
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