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Discussion Starter #1 (Edited)
Hey all. been a while for me posting. looking for some help with a idle issue. 2002 with 12000km. Jardine exhaust and K&N, petcock mod. never adjusted or jetted the carb. ran great last fall. stored with tank empty and carb drained. does not get cold here just a little below 0 c in the winter.
so ... bike starts great, but when the choke is reduced after a minute of warming up or so the idle is great for 10-20 seconds then drops about 500 rpm and cycle repeats. frequently enough to stall (espically annoying at stop lights.) runs great at RPM. still great power with the jardine. no backfiring or surging that i can tell. idle had always been good at ~1000.
new fuel - no change
tank lid open - no change
methylhydrate - no change
removed air filter - dirty but no change
cleaned plug- moderate fouling but no change
pulled carb. float bowl had a bit of grunge. float is free, gaskets good, diaphragm good. jets no obvious crap. everything blasted with carb cleaner. -no change.
oil not changed yet but level looks good and changed in november.

so wadda think? i still wonder about the jets in the carb, one flushed really well into the lower bowl, but the other not. is this just normal or could it be plugged? maybe not carb? valves, timing etc. i'm still a bit of a noob with this bike. at least i can still ride it.

thanks for any input.
 

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I had a similar problem once with a Yamaha XTZ660 being ridden after a month or so storage. Like you I stripped and cleaned the carb with no impact (in fact it felt like I cleaned it 20 times trying to find some muck I thought I must have missed).

The solution was a new spark plug which was a surprise since the old one still gave a good strong spark everytime I checked it outside the engine. For some reason the old spark plug appeared to be breaking down as soon as it started to get warm. I have no explanation why it happened after a short period of storage and not before but after the change the problem never came back.

Good Luck.
 

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Discussion Starter #3
thanks. i will definately replace it as soon as i can get my hands on a new one. does anyone run any fancy plugs in their bikes? splitfire etc?
 

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Discussion Starter #4
changed the plug to an ngk iridium. no change. added some cab cleaner to the last gallon or so of gas. going to run that through. any other thoughts? thx.
 

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KLRs run lean in the stock state and you added an exhaust that makes it even more lean. Do yourself a favor and correct the caburetor to match your exhaust then work from there.
 

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Discussion Starter #6
I was definately thinking of putting the jet kit in that i have, but then i was thinking is it better to get it running better first, or just do it? at least in this state i can still ride it, just stalls a lights (makes me look like a turd). i guess if one of the jets is plugged then changing a new one in should solve the problem. i guess the hesitation is that i dont know my way around the carb all that well. but i can always take pics and post for help i guess if i have problems. maybe tonight i'll rip into it. thx
 

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If you add a little Choke and it runs better then it is running lean. I don't know what jet kit you have but none of then are difficult or take very long to install.
There might be someone in your area that is familiar with KLRs. Where do you live?
 

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Discussion Starter #8
nope choke does not make it run better, just ups the rpm so it doesnt stall, the idle still falters. I installed the jet kit and no difference. what is next, valves? iguess i need to keep reading.
 

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Discussion Starter #10
i would have to keep mine at 15-1800 in order to prevent a stall. not an option. could the doohickey cause this problem? i am going to order the gear to get that done too.
 

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Discussion Starter #11
doing the valves now. they were out a bit, so maybe. needed done anyway. next is the doohickey ...and anything else you can think of. cheers.
 

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Discussion Starter #12
finished the valves. if anyting i would say the idle is a bit worse. idles for a bit at 12-1500 rmp then fades and stalls. i might take the top off again just to check the valve clearance now that i have put a few kms on it, but doesn't seem like that was the problem. :mad0235:maybe i'll swap the tank from the other bike to make sure there isn't a venting problem or a petcock issue. any comments if this could be the doo? my doo should be here next week, and with that an oil change and new filter.
 

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Discussion Starter #13
"keep it simple stupid" is the motto of the day. fortunately i have my wife's 2004 to steal parts from. took her tank off and put it on mine. ran fine. So at least now i know it is the fuel +/- additives or the petcock. opened the petcock because i did that mod before. looks like the little replacement diaphragm is leaking and maybe my expoy isn't holding 100%. Not fixed yet but looks like problem solved.:18:
well the other things needed doin' anyway, lol.
 

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That's just freaky...

I've been having exactly the same problems...
bike in storage
bad idle
treated gas
bad idle
changed gas
bad idle
dissassambled and totally cleaned out carb (and did the $.22 mod - actually $.09 for me)
...bad idle
So I was next going to check my petcock assy (and then valves) and thought I'd check this forum for "inspiration", and lo and behold...
Someone with the same woes.

I'll let y'all know if we end up with exactly the same solution.
 

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Fixed with a rubber glove

Well Doc, seems you and I were on parallel paths. I took apart the petcock, and though I didn't find anything obviously wierd, I removed the guts and....

uh...well, it seemed that the point of the Hurricane Mod is to isolate the whole vacuum thing from the gas flow, so I figgerd if I could just place a "blind" gasket between the petcock side and the vacuum side, I'd be golden.

A quick internet search told me that Natural and EPDM rubbers were bad news with gas...and that Nitril and Teflon were good. So, with some hesitation, I grabbed one of my blue Nitril gloves and stretched it gently between the two sides and screwed them back together. No Epoxy. No JB Weld. No guts (except maybe my own).
I then plugged the vaccum line from the Carb, reinstalled the petcock, put everything else back together, turned the key and...

...friggen smooth!!!!

Now, I certainly consider this a temporary fix, but a fix it is. :16a:

Doc, I have a question: Is Hurricane's mod gasket a blind gasket or does it have holes in it (other than for the four screws)?
 

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Discussion Starter #16
i did the hurricane mod a while ago and the gasket he sent me finally started falling apart. it is a solid gasket. i put a rubber tube in there for now until i can get something more gas friendly. started it and it runs like a top now. now i can work on the HHO generator.
 

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Hmm...the gasket falling apart? Less than a year of life? That doesn't sound too great. What are you planning to do for the long term...another Hurricane?

So, if the gasket is full/blind, why is epoxy or JB weld required? Doesn't the gasket completely close off any access to the vacuum side?
 

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Discussion Starter #18
i think you could just JB the whole thing as long as it seals. the gasket is doing nothing except stopping it from leaking. i will have to look for a new gas safe gasket, or maybe a giant blob of silicone. not going to use another hurricane gasket. rubber for now and i check it later so see how it is holding up.
 

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I'm new here and new owner of an 89 KLR. I'm having the same issues right now. I guess the bike sat for a while with the previous owner. I put some Sea Foam yesterday but not much help.
 
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