4.60 x 17 on the rear

[David Nichols]

My 1997 KLR with 14,000 miles was running great yesterday until I ran out of gas. I was riding along and the engine cut out, it turned out I had run out of gas and I flipped to reserve and it started right up. Now I have 2 problems...first, my starter is intermittent. I can get the starter to crank when the handlebars are turned all the way to the left, but when I turn them straight it cuts out. I can actually make the starter go on and off while holding the button down and turning the bars. The other problem is: it won't start. Yesterday afternoon it was harder than normal to start while hot and once I got it started it was boggy on the lower throttle, when I opened up the throttle it ran fine. It was backfiring on downshifts as well. I suspected I had a leaky exhaust around the header and when I tightened the acorn nuts they were somewhat loose. That seemed to improve the backfiring but I only rode around the block and shut it down for the night. This morning I couldn't get it started. It ran a little when I opened the throttle but I couldn't get it to stay running. The choke had no effect. I have been starting the engine without using the choke. It has been between 60 and 90 degrees here lately and I guess I haven't needed the choke. If you recall I had a problem with the choke (enrichener) plunger sticking in the carb. It had some gouges on the outside diameter and I filed them smooth so it wouldn't hang up anymore. I need to get a replacement but I have been riding the bike for the last thousand miles with no problems. Any tips on where to start troubleshooting? Could running out of gas cause a carb circuit to get plugged? I have the OEM petcock mounted filter tube on the main side, but since the reserve side filter tube was broken off I added a hose mounted filter. It's one of the Sintered Bronze type filters that Fred sells. The carb was recently cleaned, I've run 2 cans of Seafoam thru it. I did fill up with new gas yesterday. The valve clearances were recently set to the max side. I can't see how the two problems I'm having could be related, but I have seen stranger things. -David [Non-text portions of this message have been removed]

[Mike Huber]

I had the same problem with my electrical and it turned out to be the plugs behind the speedo....One of the pins had pulled out of the plug and was causing a intermittant connection.....I re-inserted it and while I was there I cleaned all the connections with some electrical spray and shot a dab of dielectric grease in each one and haven't had a problem since.... Mike Huber Carlsbad NM To: DSN_KLR650@yahoogroups.com From: david.r.nichols@... Date: Wed, 18 Apr 2012 10:55:02 -0700 Subject: [DSN_KLR650] Starter intermittent and cold starting/backfire problem My 1997 KLR with 14,000 miles was running great yesterday until I ran out of gas. I was riding along and the engine cut out, it turned out I had run out of gas and I flipped to reserve and it started right up. Now I have 2 problems...first, my starter is intermittent. I can get the starter to crank when the handlebars are turned all the way to the left, but when I turn them straight it cuts out. I can actually make the starter go on and off while holding the button down and turning the bars. The other problem is: it won't start. Yesterday afternoon it was harder than normal to start while hot and once I got it started it was boggy on the lower throttle, when I opened up the throttle it ran fine. It was backfiring on downshifts as well. I suspected I had a leaky exhaust around the header and when I tightened the acorn nuts they were somewhat loose. That seemed to improve the backfiring but I only rode around the block and shut it down for the night. This morning I couldn't get it started. It ran a little when I opened the throttle but I couldn't get it to stay running. The choke had no effect. I have been starting the engine without using the choke. It has been between 60 and 90 degrees here lately and I guess I haven't needed the choke. If you recall I had a problem with the choke (enrichener) plunger sticking in the carb. It had some gouges on the outside diameter and I filed them smooth so it wouldn't hang up anymore. I need to get a replacement but I have been riding the bike for the last thousand miles with no problems. Any tips on where to start troubleshooting? Could running out of gas cause a carb circuit to get plugged? I have the OEM petcock mounted filter tube on the main side, but since the reserve side filter tube was broken off I added a hose mounted filter. It's one of the Sintered Bronze type filters that Fred sells. The carb was recently cleaned, I've run 2 cans of Seafoam thru it. I did fill up with new gas yesterday. The valve clearances were recently set to the max side. I can't see how the two problems I'm having could be related, but I have seen stranger things. -David [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[David Nichols]

Thanks Mike, I'll check those plugs. I forgot to say I have done the 22 cent mod. I drilled the slide with a 7/64 drill, shimmed the needle and set the pilot screw to 1.75 turns. ________________________________ From: Mike Huber To: david.r.nichols@...; dsn_klr650@yahoogroups.com Sent: Wednesday, April 18, 2012 1:29 PM Subject: RE: [DSN_KLR650] Starter intermittent and cold starting/backfire problem I had the same problem with my electrical and it turned out to be the plugs behind the speedo....One of the pins had pulled out of the plug and was causing a intermittant connection.....I re-inserted it and while I was there I cleaned all the connections with some electrical spray and shot a dab of dielectric grease in each one and haven't had a problem since.... Mike Huber Carlsbad NM To: DSN_KLR650@yahoogroups.com From: david.r.nichols@... Date: Wed, 18 Apr 2012 10:55:02 -0700 Subject: [DSN_KLR650] Starter intermittent and cold starting/backfire problem My 1997 KLR with 14,000 miles was running great yesterday until I ran out of gas. I was riding along and the engine cut out, it turned out I had run out of gas and I flipped to reserve and it started right up. Now I have 2 problems...first, my starter is intermittent. I can get the starter to crank when the handlebars are turned all the way to the left, but when I turn them straight it cuts out. I can actually make the starter go on and off while holding the button down and turning the bars. The other problem is: it won't start. Yesterday afternoon it was harder than normal to start while hot and once I got it started it was boggy on the lower throttle, when I opened up the throttle it ran fine. It was backfiring on downshifts as well. I suspected I had a leaky exhaust around the header and when I tightened the acorn nuts they were somewhat loose. That seemed to improve the backfiring but I only rode around the block and shut it down for the night. This morning I couldn't get it started. It ran a little when I opened the throttle but I couldn't get it to stay running. The choke had no effect. I have been starting the engine without using the choke. It has been between 60 and 90 degrees here lately and I guess I haven't needed the choke. If you recall I had a problem with the choke (enrichener) plunger sticking in the carb. It had some gouges on the outside diameter and I filed them smooth so it wouldn't hang up anymore. I need to get a replacement but I have been riding the bike for the last thousand miles with no problems. Any tips on where to start troubleshooting? Could running out of gas cause a carb circuit to get plugged? I have the OEM petcock mounted filter tube on the main side, but since the reserve side filter tube was broken off I added a hose mounted filter. It's one of the Sintered Bronze type filters that Fred sells. The carb was recently cleaned, I've run 2 cans of Seafoam thru it. I did fill up with new gas yesterday. The valve clearances were recently set to the max side. I can't see how the two problems I'm having could be related, but I have seen stranger things. -David [Non-text portions of this message have been removed] [Non-text portions of this message have been removed] ------------------------------------ List Sponsors - Dual Sport News: http://www.dualsportnews.com Arrowhead Motorsports: http://www.arrowheadmotorsports.com List FAQ courtesy of Chris Krok: http://www.bigcee.com/klr650faq.html Member Map: http://groups.yahoo.com/group/DSN_KLR650/app/peoplemap/view/map Group Apps: http://groups.yahoo.com/group/DSN_KLR650/grouplets/subscriptionsYahoo! Groups Links [Non-text portions of this message have been removed]

[Jeff Saline]

On Wed, 18 Apr 2012 10:55:02 -0700 (PDT) David Nichols writes:

> My 1997 KLR with 14,000 miles was running great yesterday until I ran > out of gas. I was riding along and the engine cut out, it turned out > I had run out of gas and I flipped to reserve and it started right > up. > > Now I have 2 problems...first, my starter is intermittent. I can > get the starter to crank when the handlebars are turned all the way > to the left, but when I turn them straight it cuts out. I can > actually make the starter go on and off while holding the button > down and turning the bars. > > The other problem is: it won't start.

SNIP SNIP SNIP

> -David

<><><><> <><><><> David, I'll second you checking the connections below the instrument cluster. I'm also wondering if you might have a wiring rub through issue that got both the starter circuit and the kill switch??? Only way to know is to take a look. I suppose it could be a related issue with the no crank issue but I've heard a few times in the last two months of folks running out of fuel and then immediately getting a no start or no idle condition. Might be worth spending an hour cleaning the jets in the carb. A couple of the reports were clogged pilot jets. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . ____________________________________________________________ 57 Year Old Looks 27 Local Woman Reveals Wrinkle Secret That Has Doctors Angry. http://thirdpartyoffers.juno.com/TGL3141/4f8f18258b16263e34est04vuc

[revmaaatin]

Thanks. Since I have two of these, I think I am going to try the 4.6 just for grins on the KLR650. Otherwise, I am going to have a 5 year old replacement tire for the 250 before I ever wear it out, if then. thanks. revmaaatin.

--- In DSN_KLR650@yahoogroups.com, Bill Watson wrote: > > Rev, > > I think the usual reason guys might prefer them is the lowered riding height provided by the tire. Being tall, I use the 5.10 but I haven't heard of anyone having an issue with a 4.60. > > [Non-text portions of this message have been removed] >

[Jeffrey]

I think your best solution is parting it out!

[David Nichols]

I'd probably make some money on it, but I will keep it. Update: The carb problem was the choke (enrichener) plunger. It was hanging up and not closing off. I need to replace it soon. If you recall it had some scratches on the barrel that guides it in the carb bore. I polished them out as best I could but they are still there. Before I polished them they had burrs raised up, now they are just scratches below the surface. I let my friend ride it (we swapped bikes, he has a BMW R1200C. I believe he was familiarizing himself with my controls and moved the choke lever. I liked his bike, but I'm keeping the KLR... Still dealing with the electrical problem, haven't had time to find it so I'm just starting it with the bars to the left... ________________________________ From: Jeffrey To: DSN_KLR650@yahoogroups.com Sent: Thursday, April 19, 2012 3:19 AM Subject: [DSN_KLR650] Starter intermittent and cold starting/backfire problem I think your best solution is parting it out! [Non-text portions of this message have been removed]

[Jud]

> Jeff Saline >> >> --- In DSN_KLR650@yahoogroups.com, Jeff Saline >> wrote: >> >>>> >>>> The other problem is: it won't start. >>> >>> SNIP SNIP SNIP >>> >>>> -David >>> <><><><> >>> <><><><> >>> >> >>> I suppose it could be a related issue with the no crank issue but >> I've >>> heard a few times in the last two months of folks running out of >> fuel and >>> then immediately getting a no start or no idle condition. Might >> be worth >>> spending an hour cleaning the jets in the carb. A couple of the >> reports >>> were clogged pilot jets. >>> >>> Best, >>> >>> Jeff Saline >> >> >> Checking the jets is a good idea. Running out of gas means you are >> sucking the dregs out of the bottom of the tank. Grit, rust flakes, >> all kinds of junk could be included, and could end up lodged in the >> jets, particularly the pilot jet, or elsewhere in the fuel system. I >> don't recall if there was a mention of checking the fuel flow from >> the tank, but the petcock is another place that can clog up with >> silt from the bottom of the tank. >> >>