running rough after 685 install (video)... any suggestions?

[Jeff Khoury]

I agree with Stu. Looks/sounds like a fuel problem to me... either too much or too little. (That is, if it's not valve timing... I'm not much of an expert there.) Since it will run with the choke on and instantly dies when you crack the throttle, sounds lean... like it can't draw fuel through the main. My guess is that the pilot is OK since it will run at 0 throttle with the choke on, since the KLR's carb has a traditional choke instead of an enrichener. This kind of condition can be caused by carb problems or a vacuum leak. Things I would check in order of ease / likelyhood: 1. The fuel line/petcock and emissions and vent hoses disconnect the fuel line inlet to the carb and put it into a cup... turn on the fuel and see if you get free flow. 2. Vacuum leak. Start with the choke on... mist carb cleaner around the carb and intake to see if idle speed increases, then look for leaks. Check the carb vent line (the one that everyone puts the "T" mod in) 3. The slide diaphragm make sure it's seated correctly and there are no tears and that the slide moves freely. Push the slide up and down. make sure you feel resistance from air pressure and that it returns home smoothly. Check for gouges and scratches in the slide. Make sure the rim is seated and sealed properly when you put the cap back on. 3. Carb lower end check assembly, and pay special attention to the needle inlet valve, the one controlled by the float. Check the float level. Check all the rubber o-rings that seal the jets, etc. blow out all the passages with carb cleaner. Clean the jets. 4. Emission control stuff If your bike has the EEC (Evaporative Emission Control) Make sure it's plumbed right. Mixing up the hoses on the tank can cause this, too. Tank vents must be unobstructed. Also, when you crack the throttle and it starts missing, I noticed black-ish smoke. What does the smoke smell like? Gas? Oil? Old carbon? HTH -Jeff Khoury

----- Original Message ----- From: "CA Stu" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Tuesday, June 9, 2009 11:26:02 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Re: Running rough after 685 install (video)... Any suggestions? --- In DSN_KLR650@yahoogroups.com , "Charlie Y" wrote: > > No one's got the answer here ?? > Vermonter ? Dooden ? Rev? > > assumeing that the valve clearances are ok > and ignition timing hasn't been messed up. > > something simple : > check the gas petcock maybe? the air-filter ? > > something bizarre: > valve sticking? > compression relief stuck? > > im only guessing .... > > > Start with the simple stuff. You're out of your mind for even thinking about "the bizarre stuff" in my experience. Since you just monkeyed with the carb and did the 685 kit, my two guesses are: 1) You may have lost something from inside the carb on re-assembly. It looks and sounds like a fueling problem to me. Hard to start, throttle kills it.. Do you have an inline fuel filter? Have you drained the carb bowl to make sure it is getting fuel? 2) It's possible that your timing chain is one tooth off. Good luck Thanks CA Stu [Non-text portions of this message have been removed]