[bulk] [dsn_klr650] nklr shopping timing lights

[James W. Flower]

Engine had been running fine for years and several thousand miles (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem: freeway cruising above 5000 rpm, motor would start to miss. First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco. Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it. I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again. I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm. (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet. It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle. My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap; -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring. Started with it two turns out. Result: motor stumbles and dies if I try to rev it from idle. If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die. Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four. I switched back to the OEM mixture screw: no help. (I re-installed the thumb screw). I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had. Then I removed the washer from the needle: no help! The carb is back just the way it was before I starting messing with it, except for the hole in the slide. I can't believe anything I did (intentionally) caused this. But I can't find anything I broke or put back in wrong, or didn't put back in at all. Can anybody tell me what to check next? Any suggestions appreciated. And the weather's just getting good here, too! -James

[James W. Flower]

Yes, indeed it is. Just for fun, I put the old plug back in, and the motor ran a little better for several seconds, just enough I bet to foul that plug too. I'll get back in and see why the needle's not seating. Thanks!

On Apr 7, 2014, at 10:53 PM, "GMac999" wrote: > If the needle is not seated properly, you'll get fuel pouring into the carb > off idle and it'll drown it out. Is the sparkplug, you just put in, black > from flooding? > > GregM > > -----Original Message----- > From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On > Behalf Of James W. Flower > Sent: Monday, April 07, 2014 11:56 PM > To: dsn_klr650@yahoogroups.com > Subject: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 > KLR) > > Engine had been running fine for years and several thousand miles > (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed > the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; > I ride at sea level), which helped but didn't entirely fix the stumble. > A few months ago I developed a new problem: freeway cruising above > 5000 rpm, motor would start to miss. First just occasionally, then > increasingly, missing more and more cycles at a time, until it felt like a > bucking bronco. Though the problem never began under 5000, once it started, > slowing down to under 5000 didn't fix it. I'd limp home, go out the next > day and again it ran fine until I cruised over 5000, then the problem > started again. > I discovered this in fifth on the freeway, then tested in fourth and > third and got the same problem: missing started just over 5000 rpm. (My > countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) > I thought I'd check the main jet. It looked fine, even under the > magnifying glass, but I soaked it with a denture-cleaning fizzy on general > principle. My amateur eye didn't turn up any problems with the carb,but I > didn't go over it thoroughly. > But while I was doing this, I also did the following; > -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap; > -Installed the Big Cee gravity feed petcock kit; > -Installed a new length of 1/4" fuel line; > -Drilled the forward hole in the bottom of the slide to 7/64"; > -Installed a #4 SS washer, .032" thick, under the head of the jet > needle; > -Installed a new float bowl gasket, with Copper Coat in the groove > of the bowl and grease on top of the gasket; > -Installed a CV Performance EZ-Just mixture screw, with new O-ring, > washer, and spring. Started with it two turns out. > Result: motor stumbles and dies if I try to rev it from idle. If I > start at idle and very slowly open the throttle, it'll get to 2000-2400, > then die. Once I was able to rev it up, and it stumbled like crazy > (puh-POP, puh-POP, pub-POP), then died. > It did this at every mixture screw position from one turn out to > four. I switched back to the OEM mixture screw: no help. (I re-installed > the thumb screw). I checked that I'd re-installed the slide frontwards > (drilled-out hole toward front): I had. Then I removed the washer from the > needle: no help! > The carb is back just the way it was before I starting messing with > it, except for the hole in the slide. I can't believe anything I did > (intentionally) caused this. But I can't find anything I broke or put back > in wrong, or didn't put back in at all. Can anybody tell me what to check > next? > Any suggestions appreciated. And the weather's just getting good > here, too! > -James > > > > > > ------------------------------------ > > 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 > Members Map > https://maps.google.com/maps/ms?msid=212558560286766214899.0004d0fa9f1732283 > bb6f&msa=0&ll=38.522384,-109.489746&spn=6.831383,9.624023Yahoo Groups Links > > >

[James W. Flower]

GregM-  You were right, and I'm a dope.  I had the needle threaded down through the bottom of the spring seat, rather than sitting under it.  Back to normal now, but the stumble's still there.  I'll add another washer.  I started with one because the recommended total thickness seems to be .040-.050", but my washers are all a fat .030".  Thanks again!-James

[b]From: [/b]"James W. Flower" [b]Subject: [/b][b]Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)[/b] [b]Date: [/b]April 7, 2014 11:31:16 PM PDT [b]To: [/b]"GMac999" [b]Cc: [/b]"KLR650 DSN_KLR650@yahoogroups.com" dsn_klr650@yahoogroups.com> Yes, indeed it is.  Just for fun, I put the old plug back in, and the motor ran a little better for several seconds, just enough I bet to foul that plug too.  I'll get back in and see why the needle's not seating.  Thanks! On Apr 7, 2014, at 10:53 PM, "GMac999" wrote: If the needle is not seated properly, you'll get fuel pouring into the carb off idle and it'll drown it out.  Is the sparkplug, you just put in, black from flooding? GregM -----Original Message----- From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of James W. Flower Sent: Monday, April 07, 2014 11:56 PM To: dsn_klr650@yahoogroups.com Subject: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR) Engine had been running fine for years and several thousand miles (13,XXX miles on odometer).  I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up.  It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem:  freeway cruising above 5000 rpm, motor would start to miss.  First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco.  Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it.  I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again. I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm.  (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet.  It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle.  My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap; -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring.  Started with it two turns out. Result:  motor stumbles and dies if I try to rev it from idle.  If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die.  Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four.  I switched back to the OEM mixture screw: no help.  (I re-installed the thumb screw).  I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had.  Then I removed the washer from the needle: no help! The carb is back just the way it was before I starting messing with it, except for the hole in the slide.  I can't believe anything I did (intentionally) caused this.  But I can't find anything I broke or put back in wrong, or didn't put back in at all.  Can anybody tell me what to check next? Any suggestions appreciated.  And the weather's just getting good here, too! -James ------------------------------------ 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 Members Map https://maps.google.com/maps/ms?msid=212558560286766214899.0004d0fa9f1732283 bb6f&msa=0&ll=38.522384,-109.489746&spn=6.831383,9.624023Yahoo Groups Links To visit your group on the web, go to:   http://groups.yahoo.com/group/DSN_KLR650/ Your email settings:   Individual Email | Traditional To change settings online go to:   http://groups.yahoo.com/group/DSN_KLR650/join   (Yahoo! ID required) To change settings via email:   DSN_KLR650-digest@yahoogroups.com   DSN_KLR650-fullfeatured@yahoogroups.com To unsubscribe from this group, send an email to:   DSN_KLR650-unsubscribe@yahoogroups.com Your use of Yahoo Groups is subject to:   https://info.yahoo.com/legal/us/yahoo/utos/terms/

[GMac999]

You’re not the only one that has done that.  (looking over shoulder at my ’95).  I got help several years ago from the group about it and glad to return the favor.

 

GregM

 

[b]From:[/b] James W. Flower [mailto:jwflower53@...] [b]Sent:[/b] Tuesday, April 08, 2014 2:10 AM [b]To:[/b] GMac999 [b]Cc:[/b] KLR650 DSN_KLR650@yahoogroups.com [b]Subject:[/b] Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)

 

GregM-  You were right, and I'm a dope.  I had the needle threaded down through the bottom of the spring seat, rather than sitting under it.  Back to normal now, but the stumble's still there.  I'll add another washer.  I started with one because the recommended total thickness seems to be .040-.050", but my washers are all a fat .030".  

Thanks again!

-James

[b]From: [/b]"James W. Flower"

[b]Subject: Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)[/b]

[b]Date: [/b]April 7, 2014 11:31:16 PM PDT

[b]To: [/b]"GMac999"

[b]Cc: [/b]"KLR650 DSN_KLR650@yahoogroups.com" dsn_klr650@yahoogroups.com>

 

Yes, indeed it is.  Just for fun, I put the old plug back in, and the motor ran a little better for several seconds, just enough I bet to foul that plug too.  I'll get back in and see why the needle's not seating.  Thanks!

On Apr 7, 2014, at 10:53 PM, "GMac999" wrote:

If the needle is not seated properly, you'll get fuel pouring into the carb off idle and it'll drown it out.  Is the sparkplug, you just put in, black from flooding? GregM -----Original Message----- From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of James W. Flower Sent: Monday, April 07, 2014 11:56 PM To: dsn_klr650@yahoogroups.com Subject: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)             Engine had been running fine for years and several thousand miles (13,XXX miles on odometer).  I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up.  It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble.             A few months ago I developed a new problem:  freeway cruising above 5000 rpm, motor would start to miss.  First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco.  Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it.  I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again.             I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm.  (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.)             I thought I'd check the main jet.  It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle.  My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly.             But while I was doing this, I also did the following;             -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap;             -Installed the Big Cee gravity feed petcock kit;             -Installed a new length of 1/4" fuel line;             -Drilled the forward hole in the bottom of the slide to 7/64";             -Installed a #4 SS washer, .032" thick, under the head of the jet needle;             -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket;             -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring.  Started with it two turns out.             Result:  motor stumbles and dies if I try to rev it from idle.  If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die.  Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died.             It did this at every mixture screw position from one turn out to four.  I switched back to the OEM mixture screw: no help.  (I re-installed the thumb screw).  I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had.  Then I removed the washer from the needle: no help!             The carb is back just the way it was before I starting messing with it, except for the hole in the slide.  I can't believe anything I did (intentionally) caused this.  But I can't find anything I broke or put back in wrong, or didn't put back in at all.  Can anybody tell me what to check next?             Any suggestions appreciated.  And the weather's just getting good here, too! -James             ------------------------------------ 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 Members Map https://maps.google.com/maps/ms?msid=212558560286766214899.0004d0fa9f1732283 bb6f&msa=0&ll=38.522384,-109.489746&spn=6.831383,9.624023Yahoo Groups Links To visit your group on the web, go to:   http://groups.yahoo.com/group/DSN_KLR650/ Your email settings:   Individual Email | Traditional To change settings online go to:   http://groups.yahoo.com/group/DSN_KLR650/join   (Yahoo! ID required) To change settings via email:   DSN_KLR650-digest@yahoogroups.com   DSN_KLR650-fullfeatured@yahoogroups.com To unsubscribe from this group, send an email to:   DSN_KLR650-unsubscribe@yahoogroups.com Your use of Yahoo Groups is subject to:   https://info.yahoo.com/legal/us/yahoo/utos/terms/

 

 

[John Biccum]

Locate the white plug that feeds the low voltage side of the coil.  Remove, clean with contact cleaner, fill plug with dielectric grease, reinstall.  Here is where to find the white plug:

 

http://johnbiccum.smugmug.com/Motorcycl ... pan class="ygrps-yiv-837544675MsoNormal">  

 

[b]From:[/b] DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] [b]On Behalf Of [/b]James W. Flower [b]Sent:[/b] Monday, April 7, 2014 21:56 [b]To:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)

 

 

Engine had been running fine for years and several thousand miles (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem: freeway cruising above 5000 rpm, motor would start to miss. First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco. Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it. I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again. I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm. (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet. It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle. My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap; -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring. Started with it two turns out. Result: motor stumbles and dies if I try to rev it from idle. If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die. Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four. I switched back to the OEM mixture screw: no help. (I re-installed the thumb screw). I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had. Then I removed the washer from the needle: no help! The carb is back just the way it was before I starting messing with it, except for the hole in the slide. I can't believe anything I did (intentionally) caused this. But I can't find anything I broke or put back in wrong, or didn't put back in at all. Can anybody tell me what to check next? Any suggestions appreciated. And the weather's just getting good here, too! -James

[James W. Flower]

Glenn-  Don't have a spare but will use the test drill in the Clymer manual.  Thanks for the tip.-James On Apr 7, 2014, at 11:08 PM, Glenn Sturley wrote:

Hello James,From a reading of your problem it seems to me that it may be coil breakdown. When the ignition coil gets hot it can break down at the higher revs. I had exactly the same problem with a HondaXL250. It wouldn't go faster than 40kph and eventually just stopped.Just a thought, try a different known coil. CheersGlenn

[James W. Flower]

John-  Thanks, did that, no help.  -James On Apr 8, 2014, at 9:54 AM, John Biccum wrote:

Locate the white plug that feeds the low voltage side of the coil.  Remove, clean with contact cleaner, fill plug with dielectric grease, reinstall.  Here is where to find the white plug: http://johnbiccum.smugmug.com/Motorcycles/Misc-KLR-photos/497409_bP982t#!i=2596412262&k=s4Zhk3D  [b]From:[/b] DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] [b]On Behalf Of [/b]James W. Flower [b]Sent:[/b] Monday, April 7, 2014 21:56 [b]To:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)   Engine had been running fine for years and several thousand miles (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem: freeway cruising above 5000 rpm, motor would start to miss. First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco. Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it. I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again.  I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm. (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet. It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle. My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap;  -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring. Started with it two turns out. Result: motor stumbles and dies if I try to rev it from idle. If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die. Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four. I switched back to the OEM mixture screw: no help. (I re-installed the thumb screw). I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had. Then I removed the washer from the needle: no help!  The carb is back just the way it was before I starting messing with it, except for the hole in the slide. I can't believe anything I did (intentionally) caused this. But I can't find anything I broke or put back in wrong, or didn't put back in at all. Can anybody tell me what to check next? Any suggestions appreciated. And the weather's just getting good here, too! -James

[James W. Flower]

John-  Another good tip, thanks.  -James On Apr 8, 2014, at 9:14 PM, "John Biccum" wrote:

Still think its electrical, not fuel system. I d check the plug cap next. The plug cap has a thread like a woodscrew. Unscrew it (counterclockwise) then cut off about a inch of plug wire, then give the screw threads a bit of dialectic grease before screwing the plug cap back on. Over time that connection gets loose or corroded and will show up as a miss when engine under load at 5k.   [b]From:[/b] James W. Flower [mailto:jwflower53@yahoo.com]  [b]Sent:[/b] Tuesday, April 8, 2014 20:40 [b]To:[/b] John Biccum [b]Cc:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)  John-  Thanks, did that, no help.  -James  On Apr 8, 2014, at 9:54 AM, John Biccum wrote: Locate the white plug that feeds the low voltage side of the coil.  Remove, clean with contact cleaner, fill plug with dielectric grease, reinstall.  Here is where to find the white plug: http://johnbiccum.smugmug.com/Motorcycles/Misc-KLR-photos/497409_bP982t#!i=2596412262&k=s4Zhk3D  [b]From:[/b] DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] [b]On Behalf Of [/b]James W. Flower [b]Sent:[/b] Monday, April 7, 2014 21:56 [b]To:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)  Engine had been running fine for years and several thousand miles (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem: freeway cruising above 5000 rpm, motor would start to miss. First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco. Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it. I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again.  I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm. (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet. It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle. My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap;  -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring. Started with it two turns out. Result: motor stumbles and dies if I try to rev it from idle. If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die. Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four. I switched back to the OEM mixture screw: no help. (I re-installed the thumb screw). I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had. Then I removed the washer from the needle: no help!  The carb is back just the way it was before I starting messing with it, except for the hole in the slide. I can't believe anything I did (intentionally) caused this. But I can't find anything I broke or put back in wrong, or didn't put back in at all. Can anybody tell me what to check next? Any suggestions appreciated. And the weather's just getting good here, too! -James

 

[RobertWichert]

It is possible to cover the slide hole with the needle clip thingy. If you do that the slide won't lift and well, it don't run so good. You have to look down at the clip thingy from the inside of the slide and make sure that the hole is not blocked. Been there, done that. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 4/8/2014 9:34 PM, James W. Flower wrote:

John- Another good tip, thanks. -James On Apr 8, 2014, at 9:14 PM, "John Biccum" wrote: Still think its electrical, not fuel system. I d check the plug cap next. The plug cap has a thread like a woodscrew. Unscrew it (counterclockwise) then cut off about a inch of plug wire, then give the screw threads a bit of dialectic grease before screwing the plug cap back on. Over time that connection gets loose or corroded and will show up as a miss when engine under load at 5k. [b]From:[/b] James W. Flower [jwflower53@yahoo.com] [b]Sent:[/b] Tuesday, April 8, 2014 20:40 [b]To:[/b] John Biccum [b]Cc:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR) John- Thanks, did that, no help. -James On Apr 8, 2014, at 9:54 AM, John Biccum wrote:

Locate the white plug that feeds the low voltage side of the coil. Remove, clean with contact cleaner, fill plug with dielectric grease, reinstall. Here is where to find the white plug: http://johnbiccum.smugmug.com/Motorcycles/Misc-KLR-photos/497409_bP982t#!i=2596412262&k=s4Zhk3D [b]From:[/b] DSN_KLR650@yahoogroups.com [DSN_KLR650@yahoogroups.com] [b]On Behalf Of [/b]James W. Flower [b]Sent:[/b] Monday, April 7, 2014 21:56 [b]To:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR) Engine had been running fine for years and several thousand miles (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem: freeway cruising above 5000 rpm, motor would start to miss. First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco. Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it. I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again. I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm. (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet. It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle. My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap; -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring. Started with it two turns out. Result: motor stumbles and dies if I try to rev it from idle. If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die. Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four. I switched back to the OEM mixture screw: no help. (I re-installed the thumb screw). I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had. Then I removed the washer from the needle: no help! The carb is back just the way it was before I starting messing with it, except for the hole in the slide. I can't believe anything I did (intentionally) caused this. But I can't find anything I broke or put back in wrong, or didn't put back in at all. Can anybody tell me what to check next? Any suggestions appreciated. And the weather's just getting good here, too! -James

[Fred Hink]

Arcing inside the wire at the sparkplug cap will burn away the conductor and is easily fixed by trimming back the burnt out part.  Usually about 1/2 or so.  Another thing you want to check is the resistor inside the cap.  Some caps will use a slotted brass connector inside the cap that can be removed with a screwdriver.  This will give you access to the resistor and spring.  If this brass connector is loose or the resistor is bad or the spring is weak or missing, this could cause a misfire.   Fred http://www.arrowheadmotorsports.com   [b]From:[/b] jwflower53@... [b]Sent:[/b] Tuesday, April 08, 2014 10:34 PM [b]To:[/b] johnbiccum@... [b]Cc:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR)     John-  Another good tip, thanks.  -James   On Apr 8, 2014, at 9:14 PM, "John Biccum" wrote:

Still think its electrical, not fuel system.   I d check the plug cap next. The plug cap has a thread like a woodscrew. Unscrew it (counterclockwise) then cut off about a inch of plug wire, then give the screw threads a bit of dialectic grease before screwing the plug cap back on.   Over time that connection gets loose or corroded and will show up as a miss when engine under load at 5k.       [b]From:[/b] James W. Flower [mailto:jwflower53@yahoo.com]  [b]Sent:[/b] Tuesday, April 8, 2014 20:40 [b]To:[/b] John Biccum [b]Cc:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] Re: [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR) John-  Thanks, did that, no help.  -James On Apr 8, 2014, at 9:54 AM, John Biccum wrote: [quote] Locate the white plug that feeds the low voltage side of the coil.  Remove, clean with contact cleaner, fill plug with dielectric grease, reinstall.  Here is where to find the white plug: http://johnbiccum.smugmug.com/Motorcycles/Misc-KLR-photos/497409_bP982t#!i=2596412262&k=s4Zhk3D [b]From:[/b] DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] [b]On Behalf Of [/b]James W. Flower [b]Sent:[/b] Monday, April 7, 2014 21:56 [b]To:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Help! 22-cent mod renders motor non-running!?!?!? ('99 KLR) Engine had been running fine for years and several thousand miles (13,XXX miles on odometer). I'd had some off-idle stumble so I'd exposed the mixture screw and opened it up. It worked best at 1-1/4 (1300 RPM IDLE; I ride at sea level), which helped but didn't entirely fix the stumble. A few months ago I developed a new problem: freeway cruising above 5000 rpm, motor would start to miss. First just occasionally, then increasingly, missing more and more cycles at a time, until it felt like a bucking bronco. Though the problem never began under 5000, once it started, slowing down to under 5000 didn't fix it. I'd limp home, go out the next day and again it ran fine until I cruised over 5000, then the problem started again.  I discovered this in fifth on the freeway, then tested in fourth and third and got the same problem: missing started just over 5000 rpm. (My countershaft sprocket is 14 teeth; 5000 is 65 mph actual.) I thought I'd check the main jet. It looked fine, even under the magnifying glass, but I soaked it with a denture-cleaning fizzy on general principle. My amateur eye didn't turn up any problems with the carb,but I didn't go over it thoroughly. But while I was doing this, I also did the following; -Installed a new spark plug, NGK DPR8EIX-9 (Irideum), .034" gap;  -Installed the Big Cee gravity feed petcock kit; -Installed a new length of 1/4" fuel line; -Drilled the forward hole in the bottom of the slide to 7/64"; -Installed a #4 SS washer, .032" thick, under the head of the jet needle; -Installed a new float bowl gasket, with Copper Coat in the groove of the bowl and grease on top of the gasket; -Installed a CV Performance EZ-Just mixture screw, with new O-ring, washer, and spring. Started with it two turns out. Result: motor stumbles and dies if I try to rev it from idle. If I start at idle and very slowly open the throttle, it'll get to 2000-2400, then die. Once I was able to rev it up, and it stumbled like crazy (puh-POP, puh-POP, pub-POP), then died. It did this at every mixture screw position from one turn out to four. I switched back to the OEM mixture screw: no help. (I re-installed the thumb screw). I checked that I'd re-installed the slide frontwards (drilled-out hole toward front): I had. Then I removed the washer from the needle: no help!  The carb is back just the way it was before I starting messing with it, except for the hole in the slide. I can't believe anything I did (intentionally) caused this. But I can't find anything I broke or put back in wrong, or didn't put back in at all. Can anybody tell me what to check next? Any suggestions appreciated. And the weather's just getting good here, too! -James

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