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Discussion Starter #1 (Edited)
Okay guys, I'm in need of some desperate help here. About a month ago, I was riding back to my base (about 200 miles) on my 2009 KLR (stock, no mods... yet) when about 3/4ths the way there I started noticing the RPM's "ticking" and losing power intermittently like it was running out of fuel. I didn't think much of it, reached down and switched my petcock to reserve and continued on.
Well, the surging in RPM's started to get worse, and it started to skip and buck, almost exactly like it was running out of gas. I was able to get it to a gas station to fill up, thinking that was the problem. I started the bike again, went on my way and about five minutes later it started happening again. Except, it was worse. It started to backfire, buck, stutter and the RPMs would have a seizure at about 3,000-4,000. Finally, it died on me and I got it off the road and into a gas station. I was able to start the bike, and it will idle- however any time I try to put it in gear and let out the clutch, it will die like I've got the kickstand down.

Now, I know you're probably thinking "It's totally the sidestand switch malfunctioning" but here's the issue- I got the bike home, tore it apart and ran it with the sidestand switch bypassed. Still having issues.

I took apart the carb, looked as clean as anything.
Float was not hung up, I had gas in the float bowl.
The fuel lines are good and stable, not collapsing.
I'm getting good vacuum from the carb to the petcock.
The petcock is stock, and it's flowing fine.
The coil is at 16k ohms resistance from spark plug cap to positive terminal.
I have yet to check the CDI- I have reason to suspect it may be electrical.
No air leaks have been found so far, still checking.
Just did a valve adjustment three days ago. No change in issue.
When I took the carb out, the needle was fine, diaphragm was patent and the float had no fuel in it. I didn't see any blockage.
I have tried running it with and without the gas cap open, no change.
I've looked for shorts in the electrical system but have yet to find any.
No Corrosion on the battery terminals or wires.
The spark plug was burning pretty hot; but was normal for its mileage.
New spark plug.
New Air Filter
No difference in problem with choke in or out.

I have yet to check the clutch switch, the CDI, the voltage regulator and the stator.

What in the world is going on with my motorcycle??? I'm absolutely stumped, my dad (who knows KLR's like the back of his hand) is stumped, and the mechanics are stumped. We simply can't find anything that's causing this! I'll post a video as soon as I get home this weekend to show y'all.

Thanks y'all!
 

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Could be a loose battery connection, or a bad battery.

Have you checked the voltage reg at the battery?

Could be a CDI dying slow or a wire rub causing a ground short.

Are you sure the main jet is clear.

Has the bike been sitting for awhile with ethanol fuel?
 

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Discussion Starter #3
Could be a loose battery connection, or a bad battery.

Have you checked the voltage reg at the battery?

Could be a CDI dying slow or a wire rub causing a ground short.

Are you sure the main jet is clear.

Has the bike been sitting for awhile with ethanol fuel?
I've made sure to tighten, clean and test the battery. Everything is they way it should with it. I haven't checked the voltage reg, but I made sure to drain the fuel out of the tank and carb when it died on me as to not let the fuel turn to water. When I disassembled the carb the Jets looked fine, there was no clog or blockage that I could see.
 

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I have nothing constructive to add, but you got it, man. You keep checking off what it's not. You're already way beyond me. (I was going to recommend the gas cap venting, it's my go to). ;)

Keep thinking. And seafoam never hurt any bike I've had and I've seen it fix some pretty weird stuff. Or it's $7 worth of snake oil depending on your ideology. Good luck.
 
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