Engine problems....

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litekpr

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Hey all,

Hoping for some help on a recent problem with my '03 KLR650. Bought the bike about four weeks ago... put 4000 km's on it. It's my first bike... so you may notice some newbie problems here. I'm going to give a bit of history in case it helps shed some light on things.

The weekend I bought the bike (25k on it) I went for a dual sport ride in the Salmon Arm area with a couple guys I met on this site. Spent most of the ride at the back of the pack in a cloud of dust. Managed to clean the gunk out of my lungs with liberal washings of beer. However, the beer didn't have the same effect on the KLR! My first mistake was not changing/cleaning air filter after this ride. It would be another 2500 km's before I looked at it (will get to that later).

I did another solo trip down into the Boundary country putting on another 1500 km's. Lot's of dirt riding, lot's of power, no noticeable problems. Nice to not be riding in a dust cloud. The bike now has about 27k on it. Then I used the bike for local meanderings...

The bike was using some oil but nothing that seemed out of the ordinary to me. What it did use I put down to the extremely hot weather, riding conditions, etc. It used about a quart in 3000 km's. Is this too much considering the conditions? I am using 10w40 synthetic motorbike specific oil.

Then I packed the bike up and headed off for Prince Rupert taking some excellent backroads across to Quesnel. South of Likely the bike suddenly started to stutter and lurch and lose some power. I checked the oil and it was very low. I limped into a resort and bought some oil. All they had was 10w30 so that is what I used. It took a quart and that brought it up to a nice level. Not sure if the two are related but when I left the resort the bike was running fine again.

I flew by a couple KTM 950's on my way to Quesnel... course, they were in a restaurant having lunch (and they were going the other way)....

In PG I checked the oil again and somehow close to a quart had disappeared in a matter of about 350 km's. No visible leaks anywhere. Small amounts of soot on tailpipe but nothing too bad. I topped up with 10w40 synthetic in PG.

A couple hours later I arrived in Burns Lake where the bike was once again stuttering and lurching and underpowered. The following day I changed the spark plug, changed the oil (10w30 synthetic... no 10-40 in BL), and had a look at the air filter. The air filter was a disgrace. It was caked with dried dust and dirt. I washed it, dried it, put new oil on it, and installed it in the bike. Took the bike for a ride and it ran like a charm... no stuttering and as far as I could tell full power.

The next morning I took off for Prince Rupert and the bike ran wonderfully. For about an hour... then it started doing the same thing again... stuttering, lurching, and losing power. I hobbled in to Terrace with the bike barely capable of 105 km/h.

At this time it was lurching significantly, there was very little power, and when I rev the bike to 4000 rpm it surges significantly instead of revving smoothly.

During the whole time I've had the bike it has never over heated, never made any appreciable strange noices, there was no metal on the magnetic oil plug, it doesn't smoke, and it starts and idles very nicely.

I am thinking the carbs are gummed up because I ran it for 2500 km's with a disgustingly dirty air filter! But I am not sure... any one have any ideas or run across the same problem?

Any help would be much appreciated!

Thanks!
 

Yak_KLR650

New member
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KLRs will consume oil if you run at high RPM for extended periods. What you describe sounds excessive though. I have never needed to add oil between oil changes.

Is this the bike you bought from Jamie in Williams Lake? If so, give him a call and ask him (he's a decent guy and a good mechanic). I have heard of full synthetic being too slippery, so that it can get past the rings and you burn more oil. That sounds weird to me, but maybe others can shed some light.

You might want to post this question on some of the KLR specific boards like:

http://autos.groups.yahoo.com/group/DSN_klr650/or

http://www.klr650.net/forums/

Good luck.
 
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litekpr

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Thanks Yak,

I'll try one of those other sites... I will also give Jamie a call...

When I am on the highway I am often doing around 140/ dirt roads usually between 80-120. Another fellow also mentioned that they use oil at sustained high speeds. What about the emission controls for oil vapour? Was reading somewhere that the vapourized oil is fed back into the motor to be burned. You'd think going through that much oil there would be huge soot buil-up in the pipe. Or, that I would notice something somewhere...

I am hoping the rough running is just dirty carbs... the oil use I have no idea about??? You'd think if something was that seriously messed up inside that I'd either hear it or see something... and the fact that it starts and idles nicely really has me wondering.

Thanks... I'll keep digging around!
 

Yak_KLR650

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There's only one carb. Could be a piece of crud blocking one of the jets (?). I over oiled my air filter once and it stumbled and hesitated when I opened the throttle, but started and idle fine.

Putting oil on the air filter before it is totally dry (after cleaning), traps the water in the filter medium which makes a really good barrier to air flow.

Carbs confuse me so I can't offer any advice there, but it sounds like not enough air or not enough fuel when you try to apply power. Air filter or jets.

Have fun!
 

klrman

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I had that problem of stumbling and surging and losing power on my RM-125 years ago and it ended up being the ignition coil. It always started playing up midway through a race and I could not figure it out for quite some time why it was doing that. First I thought it was a carb issue or bad gas and many other things and then it ended up being just the ignition coil going south.

....and I know how you feel about eating other peoples dust..ha... that's why I tend to ride alone lately in the dry conditions as my lungs do not have air filters..
 

Yak_KLR650

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Wouldn't a coil problem show up across the power band? Not just under throttle? Or after it had heated up bit?
 

joker650

Active member
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A bad (weak) coil or sparkplug will show up more under load than at idle.
 
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litekpr

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Thanks for the ideas guys...

The fellows over at KLR650.net seem to think it is a carb or vacuum line problem. This would also be the way I am leaning, just judging from the behaviour of the bike. They are recommending cleaning the carb, checking the vacuum line for kinks, checking petcock in vacuum line, and adding Seafoam or Heet to a tank of gas. Any of you used either before?

I can't get to the bike at the moment (I'm at work), and it will be a while before I "get out," but I appreciate the help. I left the bike at the Kawi dealer in Terrace (had to get to work)... but the mechanic is on holiday until the beginning of September. Would be nice to come off the shift with the bike ready to go... but then it would also be nice to trouble shoot and have a go at fixing the problem myself.

FYI... I did bleed the carb bowl to purge any water, but it was all good. I have also been told by a bike mechanic that synthetic runs too thin and gets "crushed" going through the gears. He recommended running 20-40 or even 20-50 weight, good old fashioned oil! What are you guys using in your thumpers?

Thanks again,

Erik
 

klrman

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I guess I did not read this thread correctly as my coil only acted up under load when the engine was pretty warm.

There is a few stories about synthetic running thin, but good synthetic oil is supposed to be much more uniform in molecules or whatever than crude oil which has so many impurities in it. I was reading on the thumper forum that a lot of 4 stroke race bikes use shell rotella 15W40 as it is heavy duty and can take the impact on the gearbox much better than synthetics. Love to know the truth on this one one day.
 
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Pirate

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My longtime best friend back in the UK is a design engineer with Maclarens F1 and they use synthetic oils in thier cars. Your KLR won't have any effectwith regards todestroying synthetic oils in fact everyone should be using it in thier motorcycles............And yes I was fortunate enough to get a very nice personaltour around the brand new Maclaren facility whilst on vacation a few months ago. :tup:
 

04klr

Well-known member
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while messin with the carbatooter make sure the bottom of the vent tube isn't clogged, then you should consider installing a "T" in the line then run a second vent to a second location not so prone to mud cruddage (mine is routed to the tailsection under thefender), a clogged vent could cause you woes, the oil is another issue tho, on a 800k blast across Hwy. 20 (all of it) on a hot day with sustained fun speeds I burned 1/2 a quart, the cost of having fun!
 
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dickster

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I had similar problems with my 04 KLR. It turned out to be a wire that was grounding. There was no real pattern to it, but my bike would keep cutting out.
It might be worth looking at. I spent way to much time and money assuming it had to do with fuel.
Good luck:hb:
 

04klr

Well-known member
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04klr wrote:
while messin with the carbatooter make sure the bottom of the vent tube isn't clogged, then you should consider installing a "T" in the line then run a second vent to a second location not so prone to mud cruddage (mine is routed to the tailsection under thefender), a clogged vent could cause you woes, the oil is another issue tho, on a 800k blast across Hwy. 20 (all of it) on a hot day with sustained fun speeds I burned 1/2 a quart, the cost of having fun!
p.s. if a clear in-line filter is installed, a person can "see" if the fuel is flowing properly, this was discovered when I got bad gas from the friggin Heffly Creek gas station!
 
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litekpr

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For anyone who might be curious....

It was a bunged up carb!

Thanks for all your help.
 

tomcycle

Past President DSBC 2004 -2018
Staff member
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litekpr wrote:
For anyone who might be curious....

It was a bunged up carb!

Thanks for all your help.

I wonder if it could have had anything to do with the dirty air filter?????:shoot:

Glad you got the problem solved Ride On.

TT
 
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