[dsn_klr650] hit and miss after an hour of superslab

[SniperOne]

Ok everyone, time for some brainstorming input so I can get this fixed quickly. '00 KLR, plan to do part of the Utah Backcountry Discovery Route in a little more than a week, so I did a shake-down run up the superslab for an hour, let it rest for 30 mins, and returned home (it had been sitting for 4 weeks). After an hour at 75-80 I noted some missing and a bit of bogging about 2 miles before exiting the interstate. I had a half hour of shopping to do so it got a rest. The return trip was more of the same and it ran fine again until a couple miles before the return exit - more missing and bogging when I opened the throttle to keep speed. Backing off the throttle seemed to allow it to run ok at a lesser pace (14t front so I was running about 5500rpm). Air temp was around 95 degrees, but the gage did not indicate it was running hot. I had this kind of intermittent issue a couple years ago and converted the petcock to gravity feed, removed the diaphragms in the gas cap vent. Issued fixed.until now. Am I looking for fuel (no carb problems since I did the mods 2 years ago), air (K&N filter recently cleaned), or spark issues (plug has about 4k on it)? Randy SniperOne [Non-text portions of this message have been removed]

[bigburlybaldbeardedbiker]

Randy asked:

>After an hour at 75-80 I noted some missing and a bit of bogging about 2 >miles before exiting the interstate. Air temp was around 95 degrees, >but the gage did not indicate it was running hot.

In those temperatures and running those speeds, I would suspect that the fuel is starting to boil in the fuel line and or carb. Try insulating and putting some reflective material around the fuel line. I think Jud Jones has some experience with this. Paul Streeter [Non-text portions of this message have been removed]

[John Biccum]

Your issues sure sound like they could be fuel system related, and I'm sure you will have lots of fuel-system related suggestions to try. My '02 (A16L) presented identical symptoms, the fix was electrical. A white plug carries 12v to the low voltage (input) side of the coil. If this plug is loose the coil misfires under high loads and the resultant intermittent bogging and missing are just as you described. Here is a pic of the plug: http://johnbiccum.smugmug.com/Motorcycles/Misc-KLR-photos/497409_bP982t#!i=1 323435219 http://johnbiccum.smugmug.com/Motorcycles/Misc-KLR-photos/497409_bP982t#!i= 1323435219&k=4KVgfwN&lb=1&s=A> &k=4KVgfwN&lb=1&s=A I cleaned the plug (female) and socket (male) with electrical contact cleaner. Prior to the cleaning the contacts were notably oxidized, and the pattern of the oxidization suggested arcing. I reassembled the connection with dielectric grease to stop the arcing and keep water out. From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of SniperOne Sent: Sunday, June 23, 2013 22:37 To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Hit and Miss after an hour of superslab Ok everyone, time for some brainstorming input so I can get this fixed quickly. '00 KLR, plan to do part of the Utah Backcountry Discovery Route in a little more than a week, so I did a shake-down run up the superslab for an hour, let it rest for 30 mins, and returned home (it had been sitting for 4 weeks). After an hour at 75-80 I noted some missing and a bit of bogging about 2 miles before exiting the interstate. I had a half hour of shopping to do so it got a rest. The return trip was more of the same and it ran fine again until a couple miles before the return exit - more missing and bogging when I opened the throttle to keep speed. Backing off the throttle seemed to allow it to run ok at a lesser pace (14t front so I was running about 5500rpm). Air temp was around 95 degrees, but the gage did not indicate it was running hot. I had this kind of intermittent issue a couple years ago and converted the petcock to gravity feed, removed the diaphragms in the gas cap vent. Issued fixed.until now. Am I looking for fuel (no carb problems since I did the mods 2 years ago), air (K&N filter recently cleaned), or spark issues (plug has about 4k on it)? Randy SniperOne [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[bigburlybaldbeardedbiker]

I think the "A-Team" meant for this to go to the list, not just me. Paul ----- Forwarded by Paul D. Streeter/EG-Engrg/3M/US on 06/25/2013 08:00 AM ----- From: "A-Team" To: Date: 06/24/2013 08:04 PM Subject: Re: [DSN_KLR650] Re: Hit and Miss after an hour of superslab I think my 06 has been having the same vapor lock issues. At top speed, there has been some misses or hesitation. Similar as if there was a bit of water in the fuel or a bad plug. But I have also noted that familiar hissing/whine noise from the gas cap. Open the gas cap and there is a an obvious venting or exhaust. So your problems sound very similar to what has been going on with my bike. I was thinking maybe a jetting issue but this is my first season riding in the heat and at elevation. I bought the bike in Richmond Virginia and rode it back to NM in October-November last year. Really sounds like a classic vapor lock. I understand there is a gas cap modification? Obviously I need to make sure the fuel line is positioned as far away from a heat source as possible. Additional comments/council is appreciated. Ateam From: pdstreeter@... Sent: Monday, June 24, 2013 7:52 AM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Re: Hit and Miss after an hour of superslab Randy asked:

>After an hour at 75-80 I noted some missing and a bit of bogging about 2 >miles before exiting the interstate. Air temp was around 95 degrees, >but the gage did not indicate it was running hot.

In those temperatures and running those speeds, I would suspect that the fuel is starting to boil in the fuel line and or carb. Try insulating and putting some reflective material around the fuel line. I think Jud Jones has some experience with this. Paul Streeter [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[ron criswell]

Interesting Paul, I don't think I have had that down here running in 95 to 100 + temps in Texas. The bike did shut off once like it ran out of gas....and started shortly afterwards. I never knew why.This was in the morning though about 9:00 AM. I have run my Concours and KLR for hours around 100 to 104 with no issues. I almost sold my Connie to a 5 year old kid for $5 once gong through Childress TX. Bank sign read 104. Been pretty hot in Moab mid day. Criswell Sent from my iPad

On Jun 24, 2013, at 8:52 AM, pdstreeter@... wrote: > > Randy asked: > > >After an hour at 75-80 I noted some missing and a bit of bogging about 2 > >miles before exiting the interstate. Air temp was around 95 degrees, > >but the gage did not indicate it was running hot. > > In those temperatures and running those speeds, I would suspect that the > fuel is starting to boil in the fuel line and or carb. Try insulating and > putting some reflective material around the fuel line. I think Jud Jones > has some experience with this. > > Paul Streeter > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[owen haskell]

Hi I had a similar problem on another bike and after a lot of checking finally found it to be a faulty coil. [Non-text portions of this message have been removed]

[Ian Francisco]

Since you've done mods to the fuel system to prevent vacuum lock, I guess it wouldn't hurt to double check your work there for adequate flow to the carb. The symptoms sound like fuel starvation. Maybe the T-mod would have an effect. I just put my finger on the vent hose briefly and it caused a stumble at idle. I have not done the T-mod, I only routed the hose rearward and back instead of down. I did my carb a couple of years ago but with some dirt riding thrown in, it needed it again recently. It's only a two hour job or so, so not much excuse for not doing it periodically. There might be a problem with the coil or cdi/igniter unit that is heat related. It's hard to troubleshoot electronics without known good components to swap in. -- Ian Francisco http://www.scarletfuries.com http://www.facebook.com/pages/The-Scarlet-Furies/121218125931 [Non-text portions of this message have been removed]

[SniperOne]

Thanks for all the input on possible causes. They have ranged from fuel and heat, to a couple of electrical possibilities. Tonight will be a busy one as I work through the suggestions, Thursday is forecast to be 105 degrees and I plan to use it for another test run - though at that temp I may have to sit on a blue-ice pack! Randy SniperOne From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of SniperOne Sent: Sunday, June 23, 2013 11:37 PM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Hit and Miss after an hour of superslab Ok everyone, time for some brainstorming input so I can get this fixed quickly. '00 KLR, plan to do part of the Utah Backcountry Discovery Route in a little more than a week, so I did a shake-down run up the superslab for an hour, let it rest for 30 mins, and returned home (it had been sitting for 4 weeks). After an hour at 75-80 I noted some missing and a bit of bogging about 2 miles before exiting the interstate. I had a half hour of shopping to do so it got a rest. The return trip was more of the same and it ran fine again until a couple miles before the return exit - more missing and bogging when I opened the throttle to keep speed. Backing off the throttle seemed to allow it to run ok at a lesser pace (14t front so I was running about 5500rpm). Air temp was around 95 degrees, but the gage did not indicate it was running hot. I had this kind of intermittent issue a couple years ago and converted the petcock to gravity feed, removed the diaphragms in the gas cap vent. Issued fixed.until now. Am I looking for fuel (no carb problems since I did the mods 2 years ago), air (K&N filter recently cleaned), or spark issues (plug has about 4k on it)? Randy SniperOne [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[owen haskell]

The only way I found it was the coil was hot and I changed it for an old one I had lying around and it fixed the problem so I replaced it with a new one. [Non-text portions of this message have been removed]

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "John Biccum" wrote:

> > I cleaned the plug (female) and socket (male) with electrical contact > cleaner. Prior to the cleaning the contacts were notably oxidized, and the > pattern of the oxidization suggested arcing. I reassembled the connection > with dielectric grease to stop the arcing and keep water out. >

John, There is enough dirt in there to plant tomatoes. cough. I only regret I was not there to get equally dirty. sigh. m1.