Wilsons Sandbox

I wonder if your gas cap isn't venting properly, and you're starving for fuel at higher speeds....It could also be a vacuum petcock problem where the vacuum line is kinked or has a small hole in it. It sounds like you're starving for fuel. Had it been a vacuum slide tear, it might idle, but not accelerate at all, but that is also worth looking at AFTER checking the vacuum line from the petcock to the intake. If that isn't the issue, check the cap vant by running until it stumbles or stalls, and then open the cap. If It starts and runs fine immediately, then it was a venting issue. Are you running an inline filter that might be impeding fuel flow? Have you made the carb vent T-mod? Maybe your carb vent hose is pinched or plugged. It sounds like a fuel flow problem to me. Eric Stevens Mechancisburg, Pa --- In DSN_KLR650@yahoogroups.com, "Ron Johnson" wrote:

> > 04 with 4500mi. At 1800mi did doohickey "intact but stuck,tension

bolt over tightened",stage 2 jet kit, Laser Off Road exhaust, drilled air box, factory filter, 91 fuel only, never seen redline, 50/50 city/highway speeds vary 60-80mph, 50/50 passenger on back ridden with her comfort and safety in mind, by myself fun and grins, always warmed up before ridden and never shut off hot.

> It has been the perfect bike. Always starts instantly, hot, cold,

rain, etc., crisp throttle, pulls very smooth and strong throughout entire rpms with a slight jump in power starting at 4800rpms that continues up from there.

> Now the problem: On a 60 degree morning and 25mi of highway

speeds varying 60-70 "TRAFFIC", I found a open stretch and rolled up to 85mph, 5mi later it started to stumble and then stalled. It restarted after coasting down to 45mph. I rode the last 10mi at a slightly shaky 55 that did smooth back out by the time I reached town. After work I was gentle with it for 10mi and thinking who knows what, I attempted 70mph. The same thing happened again. Back to a shaky 55 slowly smoothing out. Yesterday, cleaned air filter, checked valves "almost exactly where I put them 1500mi ago, upper end of spec". Cleaned carb., replaced spark plug, drained gas out of gas tank completely and replaced from different gas station. Now it will start and idle and that's it. Any attempt to open the throttle results in bogging down. Cleaned the carb again, put old plug back in. Same thing, sprayed carb cleaner on intake boot while running, no change. Oil level and coolant level has not changed and is not polluted. Battery level is quite low but that should have as much affect as low tire pressure, right? I believe my attempts to fix it are not on target and what ever is wrong with it is escalating on its own. I want my bike back, much advice is needed. Lacking a compression tester I even put the bike in 5th and attempted to roll it across the garage floor, the tire mostly slid and my arms got tired. Point me in a different direction.

> > [Non-text portions of this message have been removed]

You didn't mention the condition of the plug. I suspect it was sooty from running rich. The suggestion about checking the in line fuel filter is a good one. This can be a problem as the fuel level goes down. Have you teed the carburetor vent tube? I found my vent tube pinched close by the shock spring. It was weird looking & was tight enough to hold a bit of gasoline. Sort of a pressure welded pinch. I suggest backing out the stage II carburetor setting one step at a time. Staring with the stage II jet. --- In DSN_KLR650@yahoogroups.com, "Ron Johnson" wrote:

> > 04 with 4500mi. At 1800mi did doohickey "intact but stuck,tension

bolt over tightened",stage 2 jet kit, Laser Off Road exhaust, drilled air box, factory filter, 91 fuel only, never seen redline, 50/50 city/highway speeds vary 60-80mph, 50/50 passenger on back ridden with her comfort and safety in mind, by myself fun and grins, always warmed up before ridden and never shut off hot.

> It has been the perfect bike. Always starts instantly, hot, cold,

rain, etc., crisp throttle, pulls very smooth and strong throughout entire rpms with a slight jump in power starting at 4800rpms that continues up from there.

> Now the problem: On a 60 degree morning and 25mi of highway

speeds varying 60-70 "TRAFFIC", I found a open stretch and rolled up to 85mph, 5mi later it started to stumble and then stalled. It restarted after coasting down to 45mph. I rode the last 10mi at a slightly shaky 55 that did smooth back out by the time I reached town. After work I was gentle with it for 10mi and thinking who knows what, I attempted 70mph. The same thing happened again. Back to a shaky 55 slowly smoothing out. Yesterday, cleaned air filter, checked valves "almost exactly where I put them 1500mi ago, upper end of spec". Cleaned carb., replaced spark plug, drained gas out of gas tank completely and replaced from different gas station. Now it will start and idle and that's it. Any attempt to open the throttle results in bogging down. Cleaned the carb again, put old plug back in. Same thing, sprayed carb cleaner on intake boot while running, no change. Oil level and coolant level has not changed and is not polluted. Battery level is quite low but that should have as much affect as low tire pressure, right? I believe my attempts to fix it are not on target and what ever is wrong with it is escalating on its own. I want my bike back, much advice is needed. Lacking a compression tester I even put the bike in 5th and attempted to roll it across the garage floor, the tire mostly slid and my arms got tired. Point me in a different direction.

> > [Non-text portions of this message have been removed]

By the by, my KLR is 1993 or A7 if you will. -----Original Message----- From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com]On Behalf Of genez11 Sent: Sunday, August 21, 2005 10:26 AM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] "The Doohickey" Well yesterday I changed out my doohickey. I enjoyed it so much I did it a second time just for fun. Argh!!!! My inner case gasket bowed down and allowed oil to spew out all over me and the ground right by the starter where you can't really see very well. Boy was I peed. I took my time and cleaned everything but the one part I couldn't see went south on me. The second time I got a mirror out and made sure the gasket was located on the engine case properly and now I'm good. The parts from Fred at Arrowhead were excellent and I mean perfect. The doohickey was already shaved down so the spokes were fine and no filing was necessary. Great parts Fred!!! It took me 3 hours the first time and 1 hour the second time start to finish. The key to my second attempt was leaning the bike to the right and the gaskets layed perfect on the cases. My mistake was not doing it the first time. I've been doing this mechanic stuff for quite a while and should've known better. Ahyhoo, peace of mind is mine. My doohickey was in good shape. The difference between the stock and Fred's is unbelievable. Fred's just looks so much more sturdy and professional. Shame on Kaw. Archive Quicksearch at: http://www.angelfire.com/ut/moab/klr650_data_search.html List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Yahoo! Groups Links