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Discussion Starter #1 (Edited)
Hi, this is my first post. I have been lurking for a few months since I baught a 2005 KLR from a guy at work. Much info gleened, Thanks. My problem has probably been adressed here before but for the life of me I can't find it so i'm going to ask. My bike starts and idles perfectly but when I give it any gas it dies. I have let it warm up at an idle. Tried moveing the choke in and out but nothing helps. It dies or tries to die unless I let off the gas. I just finished adjusting the valves today. Actually started the job 3 weeks ago but the local dealer didnt have the shims that I needed and after getting the run around I finaly got the shims I needed from Arrowhead today. While I was waiting for the shims I couldn't stand the suspense and started tinkering with other things while I waited. I wanted to do things one at a time so if I messed up I wouldn't have as far to look but I just couldnt stand the wait. So I bypassed the safety switches(dont' think this is the problem because it starts fine). I installed my new Jardine exhaust and the new needle it came with ,clip set in third slot from the top. I drilled the hole out in the slide with the drill bit in the jet kit. I pulled the plug and adjusted the idle mixture screw out 2 1/2 turns. I left the stock jet in per another thread on installing a Jardine (i'm at 750 ft). I pulled the baffle and drilled 3 one inch holes in the top of the air box and plugged them with UNI 1 inch filtered plugs. I also did the MB valve install in the crank breather hose.
I switched the fuses to blade fuses and I took off all of the California evaporator stuff per Marknets instructions. I also did the carb T mod. I have taken the top off the carb again to make sure that I didn't tear the rubber thingy. It looks good. Any idea what might be causeing my problems with the throttle. Did I forget to put something back together properly. If there is another thread that might answer this please direct me to it.
Thanks for your help and sorry for the book but I wanted to throw out all the info I could.

OK I tried hurricanes pet cock mod. No effect. Still will only idle. I tried hitting the gas hard and it kind of revved up a little but i couldnt hold it and it died. It is like it has a massive dead spot off idle that I cant get past.
Thanks again
 

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Float stuck not allowing enough fuel for acceleration??? WOW got me stumped on this one. Normally if the float is stuck it will run rough and you might even see some overflow coming out of the clear tube. I assume it ran fine, till you did the mods? Does your choke feel like it is engaging, ie: you feel the normal cable pressure when moving the choke lever? Did you check the choke end that goes into the carb to make sure you didn't break it and cause a vacuum leak at the carb? These are easy to break when moving the carb around to work on. I am just throwing out some ideas to check. Am hoping someone else might have the answer from previous experience. Good luck and keep us posted. Hope you enjoy the Jardine once you get the bike up and running, I think you will be pleasantly surprised with the difference in power. I too have Hurricanes mod, but just haven't had time to actually do it yet. I did pull the tank lid vent seals last year, and suggest doing that when you get time too.
 

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Discussion Starter #3
Ok I figured it out. Thanks to DXKLRs response about the float I took a closer look at some pictures of a carb all taken apart (to better understand the float setup)and realized that I had put the needle and spring seat back in wrong. I had the spring seat in upside doun with the needle on top. So if I understand it correctly the needle was being held so far out of the jet that when ever I tried to come off idle I was flooding it out. It now starts and idles perfectly. Has smooth throttle response until I hit about 3900 rpm and then starts to miss and hop up through about 5000 then seems to smooth out a bit but if I back off the throttle (to shift) and the rpms drop it starts missing and hopping again. Do I need to go up in jet size or have I got something else going on?
Thanks
 

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Usually if you don't have enough main jet, the bike will pop and backfire when accelerating. What year bike do you have? 08? or older? It still sounds like maybe some junk in the main jet. The slide does not start to slide up and open the needle from the main jet until around 3500 RPM. A half of can of Seafoam might help clean out what ever is going on in the carb. Drain the tank and put 1 gallon of fuel and the seafoam and run it up and down thru the rpm range.
 

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Discussion Starter #5
I ran some Sea Foam thru it and I also took the seals out of the gas cap. It seems to run much better but I still have an ocanional miss between 4k and 5500k. Much better than before and I can live with it for the time being until I can tear apart the carb and try to give it a good cleaning.
Thanks again DXKLR for your help.
 

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No problem. I was just throwing out some ideas. But it does sound like a bit of crud has gotten in there. Do a second round of seafoam and see if that helps more. It can't hurt. :) How are you liking the Jardine and the change in the power of the bike? I also just thought of something maybe to check again. Did you pull your plug to make sure you didn't foul it too bad, after you found out your needle was in wrong? We fouled my buddies when we tried a 155 main jet and had to put in a new plug. We are using the Iridium NGK plugs now.
 

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I think you guys hit it on the head.. There's crap in the main jet..
I'd bet a shiny quarter on it..
 

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Discussion Starter #8
Thanks, for the help, I put a new Iridium plug in when I was doing the valves but I will check it when I pull the tank to clean out the carb. The Jardine is great. The kick in the pants from the pipe and the carb work is great. Had me grinning from ear to ear until it started missing but I think we are getting a handle on that. The Jardine is actually quieter than I thought it would be. I did put in the quiet insert because I had heard people say how loud it was. With the quiet insert in I think it sounds great but not anoyingly loud. I might just have to take the insert out and have a listen. I guess when I heard loud I was thinking about my old Yamaha warrior 4wheeler. It has had a Cobra pipe on it since new in 88. Not much glass left in it. Very loud. My wife gets mad any time I start it. She is worried about what the nieghbors think or maybe she is worried because I use it to send the obnoxous nieghbor dog running. I figure if they think it is ok to let there dog bark for 45 min I should be able to rattle ther windows for a minute or two, anyway I digress. The Jardine is great, the KLR is great, life is good.
thanks again guys for all the suggestions.
 

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I ended up pulling the quiet module out. There is a definate increase in some power without it. I do not like exceptionally loud pipes, and I did not find the jardine objectionable without the insert. I think you will prefer to run it completely open. On the mod end, my buddy and I did put some Gold Wing 1500 turn down tips on the pipes. You still have the open pipe, but the turn downs direct the sound down and they actually make it 'seem' quieter than they really are.
 

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Seafoam for sure. Had the same problem and bought seafoam at any auto parts store, followed directions and presto.
 

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Discussion Starter #11
Just an update. I ran two gallons of gas and a can of Seafoam thru my bike and the hesitation is gone. Accelerates hard all the way up thru the rpms now with no missing.
Thanks again guys
 

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Before the SEA Foam, I going to suggest the filter on the fuel tap..... oh well sounds what ever it was it's gone now.....
 
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