new klr forks

[David Nichols]

My 1997 KLR650 surges when using partial throttle in windy conditions. This happens while I am riding at about 3,750 RPM - about 55 MPH. I've been trying to figure out what's going on for awhile and I'm still stumped. It may be my imagination, but this issue seems worse on a windy day. I trimmed the carb vent line last night, before I trimmed it it was hanging down below the swing arm about 4 inches. Could that have caused it? I cannot tell yet because I haven't been able to ride much since trimming the vent. I haven't done the T mod...yet. Here's the details on my KLR: 17,000 miles, I'm the second owner. 22 cent mod, drilled the slide, shimmed the main needle, set the air screw to 1.75 turns (should it be further out?). Carb has been cleaned recently and has new parts in it everywhere they can be replaced (except for slide and diaphragm, which are in good shape). Vacuum petcock, recently overhauled. Sintered brass type fuel filter, the same one Fred sells which is high flow. OEM oiled air filter with Notoil oil, recently cleaned and not over oiled. IMS tank, with a vent hose that's not clogged or kinked. New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles ago. New chain and sprockets. Eagle Mike doohickey and torsion spring. Valve clearances set to max clearance 400 miles ago. OEM exhaust, fresh gaskets with no leakage. Some more details: it doesn't pop a lot under deceleration but does have a slight popping. When I start it on a cold day the enrichener doesn't work. I can always start it by twisting the throttle until it fires and I need to keep a little throttle for about 30 seconds until it idles on it's own. If I use the enrichener, it just won't start and I'm afraid I'll flood it. I recently replaced the enrichener plunger with a new OEM one, the one I replaced had a gouge on the outside diameter of the larger part of it. Looked like someone had grabbed it with pliers. -David [Non-text portions of this message have been removed]

[RobertWichert]

Mine seems like it surges in the wind too. I have decided that it is the wind. Seriously. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 11/26/2012 11:00 AM, David Nichols wrote: > > My 1997 KLR650 surges when using partial throttle in windy conditions. > This happens while I am riding at about 3,750 RPM - about 55 MPH. I've > been trying to figure out what's going on for awhile and I'm still > stumped. It may be my imagination, but this issue seems worse on a > windy day. I trimmed the carb vent line last night, before I trimmed > it it was hanging down below the swing arm about 4 inches. Could that > have caused it? I cannot tell yet because I haven't been able to ride > much since trimming the vent. I haven't done the T mod...yet. > > Here's the details on my KLR: > 17,000 miles, I'm the second owner. > 22 cent mod, drilled the slide, shimmed the main needle, set the air > screw to 1.75 turns (should it be further out?). > Carb has been cleaned recently and has new parts in it everywhere they > can be replaced (except for slide and diaphragm, which are in good shape). > Vacuum petcock, recently overhauled. > Sintered brass type fuel filter, the same one Fred sells which is high > flow. > OEM oiled air filter with Notoil oil, recently cleaned and not over oiled. > IMS tank, with a vent hose that's not clogged or kinked. > New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles ago. > New chain and sprockets. > Eagle Mike doohickey and torsion spring. > Valve clearances set to max clearance 400 miles ago. > OEM exhaust, fresh gaskets with no leakage. > > Some more details: it doesn't pop a lot under deceleration but does > have a slight popping. When I start it on a cold day the enrichener > doesn't work. I can always start it by twisting the throttle until it > fires and I need to keep a little throttle for about 30 seconds until > it idles on it's own. If I use the enrichener, it just won't start and > I'm afraid I'll flood it. I recently replaced the enrichener plunger > with a new OEM one, the one I replaced had a gouge on the outside > diameter of the larger part of it. Looked like someone had grabbed it > with pliers. > > -David > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[David Nichols]

Maybe I should have said this before, but the engine cuts out like it's running out of gas. More throttle always makes it run but it is pretty abrupt. In a corner it's downright dangerous... One more thing, I removed the snorkle. ________________________________ From: RobertWichert To: David Nichols Cc: KLR Group DSN_KLR650@yahoogroups.com> Sent: Monday, November 26, 2012 2:25 PM Subject: Re: [DSN_KLR650] Surging when using partial throttle in windy conditions. Mine seems like it surges in the wind too. I have decided that it is the wind. Seriously. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 11/26/2012 11:00 AM, David Nichols wrote: > > My 1997 KLR650 surges when using partial throttle in windy conditions. > This happens while I am riding at about 3,750 RPM - about 55 MPH. I've > been trying to figure out what's going on for awhile and I'm still > stumped. It may be my imagination, but this issue seems worse on a > windy day. I trimmed the carb vent line last night, before I trimmed > it it was hanging down below the swing arm about 4 inches. Could that > have caused it? I cannot tell yet because I haven't been able to ride > much since trimming the vent. I haven't done the T mod...yet. > > Here's the details on my KLR: > 17,000 miles, I'm the second owner. > 22 cent mod, drilled the slide, shimmed the main needle, set the air > screw to 1.75 turns (should it be further out?). > Carb has been cleaned recently and has new parts in it everywhere they > can be replaced (except for slide and diaphragm, which are in good shape). > Vacuum petcock, recently overhauled. > Sintered brass type fuel filter, the same one Fred sells which is high > flow. > OEM oiled air filter with Notoil oil, recently cleaned and not over oiled. > IMS tank, with a vent hose that's not clogged or kinked. > New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles ago. > New chain and sprockets. > Eagle Mike doohickey and torsion spring. > Valve clearances set to max clearance 400 miles ago. > OEM exhaust, fresh gaskets with no leakage. > > Some more details: it doesn't pop a lot under deceleration but does > have a slight popping. When I start it on a cold day the enrichener > doesn't work. I can always start it by twisting the throttle until it > fires and I need to keep a little throttle for about 30 seconds until > it idles on it's own. If I use the enrichener, it just won't start and > I'm afraid I'll flood it. I recently replaced the enrichener plunger > with a new OEM one, the one I replaced had a gouge on the outside > diameter of the larger part of it. Looked like someone had grabbed it > with pliers. > > -David > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[RobertWichert]

Oh, that's very different. Mine doesn't do that. It doesn't cut out. It just gets blown around. Very different. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 11/26/2012 12:44 PM, David Nichols wrote: > > Maybe I should have said this before, but the engine cuts out like > it's running out of gas. More throttle always makes it run but it is > pretty abrupt. In a corner it's downright dangerous... > > One more thing, I removed the snorkle. > > ________________________________ > From: RobertWichert > > To: David Nichols > > Cc: KLR Group DSN_KLR650@yahoogroups.com > > > Sent: Monday, November 26, 2012 2:25 PM > Subject: Re: [DSN_KLR650] Surging when using partial throttle in windy > conditions. > > > > Mine seems like it surges in the wind too. I have decided that it is > the wind. > > Seriously. > > Robert Wichert P.Eng. LEED AP BD&C > +1 916 966 9060 > FAX +1 916 966 9068 > > =============================================== > > On 11/26/2012 11:00 AM, David Nichols wrote: > > > > My 1997 KLR650 surges when using partial throttle in windy conditions. > > This happens while I am riding at about 3,750 RPM - about 55 MPH. I've > > been trying to figure out what's going on for awhile and I'm still > > stumped. It may be my imagination, but this issue seems worse on a > > windy day. I trimmed the carb vent line last night, before I trimmed > > it it was hanging down below the swing arm about 4 inches. Could that > > have caused it? I cannot tell yet because I haven't been able to ride > > much since trimming the vent. I haven't done the T mod...yet. > > > > Here's the details on my KLR: > > 17,000 miles, I'm the second owner. > > 22 cent mod, drilled the slide, shimmed the main needle, set the air > > screw to 1.75 turns (should it be further out?). > > Carb has been cleaned recently and has new parts in it everywhere they > > can be replaced (except for slide and diaphragm, which are in good > shape). > > Vacuum petcock, recently overhauled. > > Sintered brass type fuel filter, the same one Fred sells which is high > > flow. > > OEM oiled air filter with Notoil oil, recently cleaned and not over > oiled. > > IMS tank, with a vent hose that's not clogged or kinked. > > New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles > ago. > > New chain and sprockets. > > Eagle Mike doohickey and torsion spring. > > Valve clearances set to max clearance 400 miles ago. > > OEM exhaust, fresh gaskets with no leakage. > > > > Some more details: it doesn't pop a lot under deceleration but does > > have a slight popping. When I start it on a cold day the enrichener > > doesn't work. I can always start it by twisting the throttle until it > > fires and I need to keep a little throttle for about 30 seconds until > > it idles on it's own. If I use the enrichener, it just won't start and > > I'm afraid I'll flood it. I recently replaced the enrichener plunger > > with a new OEM one, the one I replaced had a gouge on the outside > > diameter of the larger part of it. Looked like someone had grabbed it > > with pliers. > > > > -David > > > > [Non-text portions of this message have been removed] > > > > > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[Bill Kinnison]

Mine does this to a small degree too. I'm sure these being carbed engines, and varying ages, altitudes, loads, & other varying conditions, they are all a little different. But it seems like a fuel issue to me. I have seen a lot of guys say that the 22 cent mod or the KLX needle mod are necessities on this bike. I imagine they would really clean this up. - Bill On Mon, Nov 26, 2012 at 12:44 PM, David Nichols wrote:

> ** > > > Maybe I should have said this before, but the engine cuts out like it's > running out of gas. More throttle always makes it run but it is pretty > abrupt. In a corner it's downright dangerous... > > One more thing, I removed the snorkle. > > ________________________________ > From: RobertWichert > To: David Nichols > Cc: KLR Group DSN_KLR650@yahoogroups.com> > Sent: Monday, November 26, 2012 2:25 PM > Subject: Re: [DSN_KLR650] Surging when using partial throttle in windy > conditions. > > > > Mine seems like it surges in the wind too. I have decided that it is > the wind. > > Seriously. > > Robert Wichert P.Eng. LEED AP BD&C > +1 916 966 9060 > FAX +1 916 966 9068 > > =============================================== > > On 11/26/2012 11:00 AM, David Nichols wrote: > > > > My 1997 KLR650 surges when using partial throttle in windy conditions. > > This happens while I am riding at about 3,750 RPM - about 55 MPH. I've > > been trying to figure out what's going on for awhile and I'm still > > stumped. It may be my imagination, but this issue seems worse on a > > windy day. I trimmed the carb vent line last night, before I trimmed > > it it was hanging down below the swing arm about 4 inches. Could that > > have caused it? I cannot tell yet because I haven't been able to ride > > much since trimming the vent. I haven't done the T mod...yet. > > > > Here's the details on my KLR: > > 17,000 miles, I'm the second owner. > > 22 cent mod, drilled the slide, shimmed the main needle, set the air > > screw to 1.75 turns (should it be further out?). > > Carb has been cleaned recently and has new parts in it everywhere they > > can be replaced (except for slide and diaphragm, which are in good > shape). > > Vacuum petcock, recently overhauled. > > Sintered brass type fuel filter, the same one Fred sells which is high > > flow. > > OEM oiled air filter with Notoil oil, recently cleaned and not over > oiled. > > IMS tank, with a vent hose that's not clogged or kinked. > > New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles ago. > > New chain and sprockets. > > Eagle Mike doohickey and torsion spring. > > Valve clearances set to max clearance 400 miles ago. > > OEM exhaust, fresh gaskets with no leakage. > > > > Some more details: it doesn't pop a lot under deceleration but does > > have a slight popping. When I start it on a cold day the enrichener > > doesn't work. I can always start it by twisting the throttle until it > > fires and I need to keep a little throttle for about 30 seconds until > > it idles on it's own. If I use the enrichener, it just won't start and > > I'm afraid I'll flood it. I recently replaced the enrichener plunger > > with a new OEM one, the one I replaced had a gouge on the outside > > diameter of the larger part of it. Looked like someone had grabbed it > > with pliers. > > > > -David > > > > [Non-text portions of this message have been removed] > > > > > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed] > > >

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

[Ken]

I have an 09 with the 688 upgrade with klx needle and rejetted. No problems. KJE Bill Kinnison wrote:Mine does this to a small degree too. I'm sure these being carbed engines, and varying ages, altitudes, loads, & other varying conditions, they are all a little different. But it seems like a fuel issue to me. I have seen a lot of guys say that the 22 cent mod or the KLX needle mod are necessities on this bike. I imagine they would really clean this up. - Bill On Mon, Nov 26, 2012 at 12:44 PM, David Nichols wrote:

> ** > > > Maybe I should have said this before, but the engine cuts out like it's > running out of gas. More throttle always makes it run but it is pretty > abrupt. In a corner it's downright dangerous... > > One more thing, I removed the snorkle. > > ________________________________ > From: RobertWichert > To: David Nichols > Cc: KLR Group DSN_KLR650@yahoogroups.com> > Sent: Monday, November 26, 2012 2:25 PM > Subject: Re: [DSN_KLR650] Surging when using partial throttle in windy > conditions. > > > > Mine seems like it surges in the wind too. I have decided that it is > the wind. > > Seriously. > > Robert Wichert P.Eng. LEED AP BD&C > +1 916 966 9060 > FAX +1 916 966 9068 > > =============================================== > > On 11/26/2012 11:00 AM, David Nichols wrote: > > > > My 1997 KLR650 surges when using partial throttle in windy conditions. > > This happens while I am riding at about 3,750 RPM - about 55 MPH. I've > > been trying to figure out what's going on for awhile and I'm still > > stumped. It may be my imagination, but this issue seems worse on a > > windy day. I trimmed the carb vent line last night, before I trimmed > > it it was hanging down below the swing arm about 4 inches. Could that > > have caused it? I cannot tell yet because I haven't been able to ride > > much since trimming the vent. I haven't done the T mod...yet. > > > > Here's the details on my KLR: > > 17,000 miles, I'm the second owner. > > 22 cent mod, drilled the slide, shimmed the main needle, set the air > > screw to 1.75 turns (should it be further out?). > > Carb has been cleaned recently and has new parts in it everywhere they > > can be replaced (except for slide and diaphragm, which are in good > shape). > > Vacuum petcock, recently overhauled. > > Sintered brass type fuel filter, the same one Fred sells which is high > > flow. > > OEM oiled air filter with Notoil oil, recently cleaned and not over > oiled. > > IMS tank, with a vent hose that's not clogged or kinked. > > New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles ago. > > New chain and sprockets. > > Eagle Mike doohickey and torsion spring. > > Valve clearances set to max clearance 400 miles ago. > > OEM exhaust, fresh gaskets with no leakage. > > > > Some more details: it doesn't pop a lot under deceleration but does > > have a slight popping. When I start it on a cold day the enrichener > > doesn't work. I can always start it by twisting the throttle until it > > fires and I need to keep a little throttle for about 30 seconds until > > it idles on it's own. If I use the enrichener, it just won't start and > > I'm afraid I'll flood it. I recently replaced the enrichener plunger > > with a new OEM one, the one I replaced had a gouge on the outside > > diameter of the larger part of it. Looked like someone had grabbed it > > with pliers. > > > > -David > > > > [Non-text portions of this message have been removed] > > > > > > [Non-text portions of this message have been removed] > > [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]

[David Nichols]

Thanks Ken, can you tell me what number jet you're using? Any other mods? ________________________________ From: Ken To: Bill Kinnison ; David Nichols Cc: RobertWichert ; KLR Group DSN_KLR650@yahoogroups.com> Sent: Tuesday, November 27, 2012 6:42 PM Subject: Re: [DSN_KLR650] Surging when using partial throttle in windy conditions. I have an 09 with the 688 upgrade with klx needle and rejetted. No problems. KJE Bill Kinnison wrote:Mine does this to a small degree too. I'm sure these being carbed engines, and varying ages, altitudes, loads, & other varying conditions, they are all a little different. But it seems like a fuel issue to me. I have seen a lot of guys say that the 22 cent mod or the KLX needle mod are necessities on this bike. I imagine they would really clean this up. - Bill On Mon, Nov 26, 2012 at 12:44 PM, David Nichols wrote:

> ** > > > Maybe I should have said this before, but the engine cuts out like it's > running out of gas. More throttle always makes it run but it is pretty > abrupt. In a corner it's downright dangerous... > > One more thing, I removed the snorkle. > > ________________________________ > From: RobertWichert > To: David Nichols > Cc: KLR Group DSN_KLR650@yahoogroups.com> > Sent: Monday, November 26, 2012 2:25 PM > Subject: Re: [DSN_KLR650] Surging when using partial throttle in windy > conditions. > > > > Mine seems like it surges in the wind too. I have decided that it is > the wind. > > Seriously. > > Robert Wichert P.Eng. LEED AP BD&C > +1 916 966 9060 > FAX +1 916 966 9068 > > =============================================== > > On 11/26/2012 11:00 AM, David Nichols wrote: > > > > My 1997 KLR650 surges when using partial throttle in windy conditions. > > This happens while I am riding at about 3,750 RPM - about 55 MPH. I've > > been trying to figure out what's going on for awhile and I'm still > > stumped. It may be my imagination, but this issue seems worse on a > > windy day. I trimmed the carb vent line last night, before I trimmed > > it it was hanging down below the swing arm about 4 inches. Could that > > have caused it? I cannot tell yet because I haven't been able to ride > > much since trimming the vent. I haven't done the T mod...yet. > > > > Here's the details on my KLR: > > 17,000 miles, I'm the second owner. > > 22 cent mod, drilled the slide, shimmed the main needle, set the air > > screw to 1.75 turns (should it be further out?). > > Carb has been cleaned recently and has new parts in it everywhere they > > can be replaced (except for slide and diaphragm, which are in good > shape). > > Vacuum petcock, recently overhauled. > > Sintered brass type fuel filter, the same one Fred sells which is high > > flow. > > OEM oiled air filter with Notoil oil, recently cleaned and not over > oiled. > > IMS tank, with a vent hose that's not clogged or kinked. > > New Eagle Mike/Wyman Winn 688 piston, rings, and valve job 400 miles ago. > > New chain and sprockets. > > Eagle Mike doohickey and torsion spring. > > Valve clearances set to max clearance 400 miles ago. > > OEM exhaust, fresh gaskets with no leakage. > > > > Some more details: it doesn't pop a lot under deceleration but does > > have a slight popping. When I start it on a cold day the enrichener > > doesn't work. I can always start it by twisting the throttle until it > > fires and I need to keep a little throttle for about 30 seconds until > > it idles on it's own. If I use the enrichener, it just won't start and > > I'm afraid I'll flood it. I recently replaced the enrichener plunger > > with a new OEM one, the one I replaced had a gouge on the outside > > diameter of the larger part of it. Looked like someone had grabbed it > > with pliers. > > > > -David > > > > [Non-text portions of this message have been removed] > > > > > > [Non-text portions of this message have been removed] > > [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] [Non-text portions of this message have been removed]

[Mike Huber]

Ron, I know the newer forks are something like 41mm in diameter and the old ones are 38mm, so you would also have to swap the triple tree.... And if you have the older fork brace it won't swap over either. Mike Huber Carlsbad NM To: DSN_KLR650@yahoogroups.com From: judjonzz@... Date: Wed, 28 Nov 2012 19:06:31 +0000 Subject: [DSN_KLR650] Re: New KLR forks I don't know if that would be any improvement at all. Don't the post-08 forks have less travel?

--- In DSN_KLR650@yahoogroups.com, Ron Criswell wrote: > > > > Sent from my iPad > > My KLR is a '99 with Progressive springs on the forks and a large MAP aftermarket rotor. I friend just bought a trashed out '09 where someone did the doohickey but did it wrong and the engine destroyed itself due to a misplaced washer. Expensive mistake. > > Anyway, he is offering the forks, brakes and rotors to me. We will have to make a bracket for the brakes I think but no big deal as he has already done this putting V-Strom brakes on his KLR. Sound like a good idea to y'all? Are the forks on the newer KLR's better than old forks with Progressive springs? > > Criswell > [Non-text portions of this message have been removed]