need help waterpump/oil seal

[kenglena]

Hello all, I had a rebuild engine that runs great during the cool weather until we had a warm spell in the 80's and it overheats and quit while puttering in slow speed in the country. Couldnt figure it out so I suspect its electrical somewhere. Checked everything out and still will turn over but wont fire up. Then it fired up easily after it cooled down. Same thing happens twice, riding in slow speed then engine overheats and quit and will fire up after cooling down. So what do you think? Is it possible I have a bad coil or something else? thanks, Kenneth

[John Biccum]

I'd look at the coil wire where it leaves the plug cap. Remove the plug cap from the wire (turn the plug cap counterclockwise) then cut off 1/4 inch or so of wire. Put a dab of dielectric grease on the end of the wire and screw the plug cap back on. Finally seal the outside of the plug cap-plug wire junction with some RTV or similar sealant. This RTV provides a mechanical seal which helps prevent subsequent loosening from vibration. Inside the plug cap is a male thread, much like a wood screw. This tends to get loose over time causing arcing and can lead to the warm failure symptoms you describe. The coil end is similar but failure is less common there. -----Original Message----- From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of kenglena Sent: Thursday, March 02, 2006 9:41 PM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Need help... bad coil or what? Hello all, I had a rebuild engine that runs great during the cool weather until we had a warm spell in the 80's and it overheats and quit while puttering in slow speed in the country. Couldnt figure it out so I suspect its electrical somewhere. Checked everything out and still will turn over but wont fire up. Then it fired up easily after it cooled down. Same thing happens twice, riding in slow speed then engine overheats and quit and will fire up after cooling down. So what do you think? Is it possible I have a bad coil or something else? thanks, Kenneth 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 Member Map at: http://www.frappr.com/dsnklr650 Yahoo! Groups Links

[Ron Johnson]

Cheap antifreeze or the water/antifreeze mixture will make a motor run hotter than normal. Replace it YOURSELF with a proper 50/50 mix then you KNOW. Is your electric fan turning on and staying on? Is the fan running fast and strong or slow and erratic? Is the fan turning on by the time the temp gauge is at the half way mark? A LEAN carb will cause over heating but otherwise run fine. Clean it well. Don't forget the cover on the side of the carb being VERY careful of the diaphram, spring, and the very tiny rubber o-ring. Put the mixture screw at 2 1/4 turns out. I have a thumb screw and it is 1 1/8 out. If I am wrong on the mixture setting someone will quickly point that out. A vacuum leak will cause a motor to run lean which in turn means it will run hot but otherwise okay. Inspect the intake boot for tears and since you already have the carb off and out of the way, take the boot off and inspect the rubber o-ring for damage. I like to pack that o-ring in vaseline, "believing that it will keep the rubber moist, therefore swollen and better making a seal". Up to you. I do not believe electrical problems will cause overheating, but overheating can cause electrical failure. You mentioned recent rebuild. I would also consider the cooling system itself. Maybe flushing the radiator and checking for proper flow. Personally never done that, can't advise. Just my 2-cents.

----- Original Message ----- From: kenglena To: DSN_KLR650@yahoogroups.comDSN_KLR650@yahoogroups.com> Sent: Thursday, March 02, 2006 11:41 PM Subject: [DSN_KLR650] Need help... bad coil or what? Hello all, I had a rebuild engine that runs great during the cool weather until we had a warm spell in the 80's and it overheats and quit while puttering in slow speed in the country. Couldnt figure it out so I suspect its electrical somewhere. Checked everything out and still will turn over but wont fire up. Then it fired up easily after it cooled down. Same thing happens twice, riding in slow speed then engine overheats and quit and will fire up after cooling down. So what do you think? Is it possible I have a bad coil or something else? thanks, Kenneth Archive Quicksearch at: [url=http://www.angelfire.com/ut/moab/klr650_data_search.htmlhttp://www.angelfire.com/ut/moab/klr650_data_search.html> List sponsored by Dual Sport News at: www.dualsportnews.comhttp://www.dualsportnews.com/> List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.htmlhttp://www.bigcee.com/klr650faq.html> Member Map at: [url=http://www.frappr.com/dsnklr650http://www.frappr.com/dsnklr650> Yahoo! Groups Links [Non-text portions of this message have been removed]

[Bogdan Swider]

I agree with Ron J. that the basic problem isn't electrical but something amiss with the cooling system. The first thing I'd do is see if the fan is working. You'll see a wire going into the switch on the bottom of the radiator. Pull that wire off the blade and ground it on the engine or somewhere. The fan should then start spinning. You can do this simple test in 2 minutes. Bogdan

On 3/2/06 10:41 PM, "kenglena" wrote: > Hello all, > > I had a rebuild engine that runs great during the cool weather until > we had a warm spell in the 80's and it overheats and quit while > puttering in slow speed in the country. Couldnt figure it out so I > suspect its electrical somewhere. Checked everything out and still > will turn over but wont fire up. Then it fired up easily after it > cooled down. Same thing happens twice, riding in slow speed then > engine overheats and quit and will fire up after cooling down. So what > do you think? Is it possible I have a bad coil or something else? > > thanks, > Kenneth >

[Jim]

You might have two different problems. Didn't someone once have the hoses at the pump reversed? A marginal coil will act-up when it gets hot(car experience). Jim A17

--- In DSN_KLR650@yahoogroups.com, "kenglena" wrote: > > Hello all, > > I had a rebuild engine that runs great during the cool weather until > we had a warm spell in the 80's and it overheats and quit while > puttering in slow speed in the country. Couldnt figure it out so I > suspect its electrical somewhere. Checked everything out and still > will turn over but wont fire up. Then it fired up easily after it > cooled down. Same thing happens twice, riding in slow speed then > engine overheats and quit and will fire up after cooling down. So what > do you think? Is it possible I have a bad coil or something else? > > thanks, > Kenneth >

[kenglena]

Looks like I'll have to look into the carb, antifreeze, fan, and coil after I get the car back on the road for work. Any more suggestions are welcome. thanks, Kenneth

[kenglena]

Ok, I'm back to working on my bike. Took the right side cover to remove the air filter... it looks ok. Remove the radiator cap to check w/anitfreeze bulb... still good antifreeze straight from brand new 50/50 mix bottle. Started engine up to warm it up... notices antifreeze starting to get hot and thermostat is working. Gauge isnt even 1/4 way and it quits. I was puzzled cuz it wasnt even overheating and it quits sooner than before. Unplugged the wire for fan, grounded it, and it runs fine. Oil level is ok. All that from easy access so I'm gonna pull the seat and gas tank next. Wish me luck finding the problem. **DUH** just found I left choke on thats why it quits sooner. UPDATE Snipped off 1/4" both ends of plug wire and screw in boot and coil with dielectric... will see what happens later. Took top cover off to check valve clearance... they all seem within spec. Left side... 0.006" exhaust, 0.005" intake. Right side... 0.007" exhaust, 0.007" intake. Pretty much close to the bottom of spec so what y'all think? Checked, cleaned, and gapped the spark plug. Boots on both ends of carb are fine and no cracks. Gonna button it up and see if it solves anything... if not then the carb disassembly & cleaning is next. Wish me luck again. thanks, Kenneth

[kenglena]

Still no change... engine warmed up, gage reads past half, fan runs 3 times, and the engine quits roughly 15 minutes after warm up. Still scratching my head. Dunno if carb cleaning will solve it... still thinks its a bad coil. Running out of ideas.

[klr6501995]

the time of 15min makes me wonder about your gas cap venting. run the bike with the cap open and see if same result pops up. overheating could be caused by air leaks around carb boots, header gaskets, hole in the header pipe, or even base gasket. but if no popping noises then prob. no air leaks. get a air hose or something and keep the coil cool and see if your problem happens. somebody mentioned coolant hose could be mis connected. could also be related to the stator windings, heat would cause a bad solder joint to goof up.

--- In DSN_KLR650@yahoogroups.com, "kenglena" wrote: > > Still no change... engine warmed up, gage reads past half, fan runs 3 > times, and the engine quits roughly 15 minutes after warm up. Still > scratching my head. Dunno if carb cleaning will solve it... still > thinks its a bad coil. Running out of ideas. >

[Ronald Criswell]

It could be gas cap venting is clogged. I had that once and it drove me crazy till I figured that was what it was. Criswell

On Mar 6, 2006, at 4:56 PM, klr6501995 wrote: > the time of 15min makes me wonder about your gas cap venting. > run the bike with the cap open and see if same result pops up. > > overheating could be caused by air leaks around carb boots, header > gaskets, hole in the header pipe, or even base gasket. but if no > popping noises then prob. no air leaks. > > get a air hose or something and keep the coil cool and see if your > problem happens. > > somebody mentioned coolant hose could be mis connected. > > could also be related to the stator windings, heat would cause a bad > solder joint to goof up. > > > > > --- In DSN_KLR650@yahoogroups.com, "kenglena" wrote: >> >> Still no change... engine warmed up, gage reads past half, fan runs 3 >> times, and the engine quits roughly 15 minutes after warm up. Still >> scratching my head. Dunno if carb cleaning will solve it... still >> thinks its a bad coil. Running out of ideas. >> > > > > > > > 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 > Member Map at: http://www.frappr.com/dsnklr650 > Yahoo! Groups Links > > > > > >