chain adjustment with lowering links and powder coat removal

[revmaaatin]

Finally, I think I got the bike to stop stumbling. Jeff Saline and I have been chasing this phantom for over 3, tiring years (at least tiring for me) 3 years ago the 1998 KLR650 presented with a problem that only manifested itself with 90F+ temps that seemed like the bike was running out of gas...except when you went to reserve of 'enricher-full' position, it did not get better. At the worst case, The bike would barely pull itself at 35mph if the temps were above 90F; a tedious proposition at best. I was pretty sure it was a fuel delivery problem; but what? I drained the fuel bowl. I wrapped the fuel line with foil bubble wrap I changed fuel brands I Seafoam-ed treatment of the fuel in the tank until the stock price went up... Jeff Saline tore down the gas cap (it had sticking valves) I went to premium gas Made sure it was not ethanol gas. Again. changed the spark plug Tore down the gas cap again: rubber valves not perfect but flowed air. I changed the gas cap in June to a brand new gas cap from my bone pile. Stumbled along as soon as it hit the 90F+ again; so I changed back to the old gas cap. Then, changed the vacuum line to the petcock checked the float bowl fuel level serviced the air cleaner. all the while, each correction was a tedious process as we don't have a lot of consecutive 90F days...so make a change and then wait for the next hot day. It could be weeks! Sometimes months. shrug. = the temp would decrease and not have a problem for 100s of miles. shrug. But the dog days of summer are upon us, so we got some hot days ahead. Riding 10 days ago near Williston North Dakota, we were bumping 90F and the bike began to stumble again. sigh. At least I know it is not solved. cough. So fast forward to last, Saturday--the wx forecast is HOT. Like to hot for the Cat on a tin roof, hot To Hot to fish. To Hot for most Harley riders, hot. you get the picture.... After much knashing of teeth, and process of elimination, I (convinced myself) was being very methodical about the checking process as I wanted to know, what the actual item that was the ultimate fix. = only one item at a time changed, then verify: it appears/and verified at this time the only item remaining has to be a bad petcock diaphragm. So, I got busy and pulled the tank, tore down to petcock; (best done with the tank off, least you drown your work area with petrol.) During the p/c teardown, the diaphragm was wet on both sides of the diaphragm, which indicates (to me) extra fuel was being sucked into the intake and 'drowning' the bike vs. starving the bike. at least that is my present understanding...that the fuel was only supposed to be on one side of the double diaphragm. Fortunately, I possessed a new petcock diaphragm (takeoff part) purchased from the F 1 builders of the USMC diesel bikes. 70 plus miles of spirited riding today at 90F+ and nary a stumble. I am pleased, to say the least. As a side note, It appears that the diaphragm life on this petcock is ~25Kmiles +/-. The previous petcock diaphragm failed to external leak at ~25K. The bike now has 52K and has been stumbling the last 5K at temps above 90F; annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary a stumble and often drinks from the same pump/hose. Go figure. A complete OEM rebuild kit (as I recall) is ~$30. Includes all the moving parts and O-rings. The alternate fix to all this is a $20 manual petcock block off plate that Jeff Saline makes. I have that part in my pocket, and will make that change if necessary. Another item of note, examine the plate that contains the vacuum nipple. It has two holes on the inside to the plate. The center hole must be able to 'draw' vacuum easily; that is what makes the petcock flow fuel. Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny amount of air when you blow into the vacuum nipple; that lets the pressure off the petcock when the engine is shutoff. Jeff Saline and I checked a couple of these backing plates from our 'bone-pile' and some did not flow air. Does your bike stumble? Is it the diaphragm? You just won't know until you tear it down and look at it. Pay close attention to the parts orientation as you tear down the petcock...there is a little spring under the outer plate that is just dying to jump off your bench and run across the room and fall into a deep crack. cough. Launching on Wednesday for 3Ksmiles; right into the teeth of a South Dakota-Iowa-Missouri heatwave. Will know for double dog sure on Wednesday afternoon if this IS the cure. smile. revmaaatin.

[Jeff Khoury]

Stumbling when hot is almost always a symptom of being too rich. Now the cause could be many things, but it is almost invariably a mixture problem. -Jeff Khoury

----- Original Message ----- From: "revmaaatin" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Monday, August 26, 2013 4:53:46 PM Subject: [DSN_KLR650] When it is HOT, she stubles. Finally, I think I got the bike to stop stumbling. Jeff Saline and I have been chasing this phantom for over 3, tiring years (at least tiring for me) 3 years ago the 1998 KLR650 presented with a problem that only manifested itself with 90F+ temps that seemed like the bike was running out of gas...except when you went to reserve of 'enricher-full' position, it did not get better. At the worst case, The bike would barely pull itself at 35mph if the temps were above 90F; a tedious proposition at best. I was pretty sure it was a fuel delivery problem; but what? I drained the fuel bowl. I wrapped the fuel line with foil bubble wrap I changed fuel brands I Seafoam-ed treatment of the fuel in the tank until the stock price went up... Jeff Saline tore down the gas cap (it had sticking valves) I went to premium gas Made sure it was not ethanol gas. Again. changed the spark plug Tore down the gas cap again: rubber valves not perfect but flowed air. I changed the gas cap in June to a brand new gas cap from my bone pile. Stumbled along as soon as it hit the 90F+ again; so I changed back to the old gas cap. Then, changed the vacuum line to the petcock checked the float bowl fuel level serviced the air cleaner. all the while, each correction was a tedious process as we don't have a lot of consecutive 90F days...so make a change and then wait for the next hot day. It could be weeks! Sometimes months. shrug. = the temp would decrease and not have a problem for 100s of miles. shrug. But the dog days of summer are upon us, so we got some hot days ahead. Riding 10 days ago near Williston North Dakota, we were bumping 90F and the bike began to stumble again. sigh. At least I know it is not solved. cough. So fast forward to last, Saturday--the wx forecast is HOT. Like to hot for the Cat on a tin roof, hot To Hot to fish. To Hot for most Harley riders, hot. you get the picture.... After much knashing of teeth, and process of elimination, I (convinced myself) was being very methodical about the checking process as I wanted to know, what the actual item that was the ultimate fix. = only one item at a time changed, then verify: it appears/and verified at this time the only item remaining has to be a bad petcock diaphragm. So, I got busy and pulled the tank, tore down to petcock; (best done with the tank off, least you drown your work area with petrol.) During the p/c teardown, the diaphragm was wet on both sides of the diaphragm, which indicates (to me) extra fuel was being sucked into the intake and 'drowning' the bike vs. starving the bike. at least that is my present understanding...that the fuel was only supposed to be on one side of the double diaphragm. Fortunately, I possessed a new petcock diaphragm (takeoff part) purchased from the F 1 builders of the USMC diesel bikes. 70 plus miles of spirited riding today at 90F+ and nary a stumble. I am pleased, to say the least. As a side note, It appears that the diaphragm life on this petcock is ~25Kmiles +/-. The previous petcock diaphragm failed to external leak at ~25K. The bike now has 52K and has been stumbling the last 5K at temps above 90F; annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary a stumble and often drinks from the same pump/hose. Go figure. A complete OEM rebuild kit (as I recall) is ~$30. Includes all the moving parts and O-rings. The alternate fix to all this is a $20 manual petcock block off plate that Jeff Saline makes. I have that part in my pocket, and will make that change if necessary. Another item of note, examine the plate that contains the vacuum nipple. It has two holes on the inside to the plate. The center hole must be able to 'draw' vacuum easily; that is what makes the petcock flow fuel. Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny amount of air when you blow into the vacuum nipple; that lets the pressure off the petcock when the engine is shutoff. Jeff Saline and I checked a couple of these backing plates from our 'bone-pile' and some did not flow air. Does your bike stumble? Is it the diaphragm? You just won't know until you tear it down and look at it. Pay close attention to the parts orientation as you tear down the petcock...there is a little spring under the outer plate that is just dying to jump off your bench and run across the room and fall into a deep crack. cough. Launching on Wednesday for 3Ksmiles; right into the teeth of a South Dakota-Iowa-Missouri heatwave. Will know for double dog sure on Wednesday afternoon if this IS the cure. smile. revmaaatin.

[Desert Datsuns]

Does it do it all the time, or only when the bike is slow in traffic. If it only does it while stuck in traffic, or slow city riding, my bet would be vapor lock. I've had it happen on cars and bikes here in Phoenix. Ryan Phoenix, AZ revmaaatin wrote:

> > > Finally, I think I got the bike to stop stumbling. > > Jeff Saline and I have been chasing this phantom for over 3, tiring > years (at least tiring for me) > > 3 years ago the 1998 KLR650 presented with a problem that only > manifested itself with 90F+ temps that seemed like the bike was running > out of gas...except when you went to reserve of 'enricher-full' > position, it did not get better. At the worst case, > > The bike would barely pull itself at 35mph if the temps were above 90F; > a tedious proposition at best. > > I was pretty sure it was a fuel delivery problem; but what? > > I drained the fuel bowl. > > I wrapped the fuel line with foil bubble wrap > > I changed fuel brands > > I Seafoam-ed treatment of the fuel in the tank until the stock price > went up... > > Jeff Saline tore down the gas cap (it had sticking valves) > > I went to premium gas > > Made sure it was not ethanol gas. Again. > > changed the spark plug > > Tore down the gas cap again: rubber valves not perfect but flowed air. > > I changed the gas cap in June to a brand new gas cap from my bone pile. > > Stumbled along as soon as it hit the 90F+ again; so I changed back to > the old gas cap. > > Then, changed the vacuum line to the petcock > > checked the float bowl fuel level > > serviced the air cleaner. > > all the while, > > each correction was a tedious process as we don't have a lot of > consecutive 90F days...so make a change and then wait for the next hot day. > > It could be weeks! Sometimes months. > > shrug. > > = the temp would decrease and not have a problem for 100s of miles. shrug. > > But the dog days of summer are upon us, so we got some hot days ahead. > > Riding 10 days ago near Williston North Dakota, we were bumping 90F and > the bike began to stumble again. sigh. > At least I know it is not solved. cough. > > So fast forward to last, Saturday--the wx forecast is HOT. > > Like to hot for the Cat on a tin roof, hot > > To Hot to fish. > > To Hot for most Harley riders, hot. > > you get the picture.... > > After much knashing of teeth, and process of elimination, > > I (convinced myself) was being very methodical about the checking > process as I wanted to know, what the actual item that was the ultimate > fix. > > = only one item at a time changed, > > then verify: > > it appears/and verified at this time the only item remaining has to be a > bad petcock diaphragm. > > So, I got busy and pulled the tank, > > tore down to petcock; (best done with the tank off, least you drown your > work area with petrol.) > > During the p/c teardown, the diaphragm was wet on both sides of the > diaphragm, which indicates (to me) extra fuel was being sucked into the > intake and 'drowning' the bike vs. starving the bike. > > at least that is my present understanding...that the fuel was only > supposed to be on one side of the double diaphragm. > > Fortunately, I possessed a new petcock diaphragm (takeoff part) > purchased from the F 1 builders of the USMC diesel bikes. > > 70 plus miles of spirited riding today at 90F+ and nary a stumble. > I am pleased, to say the least. > > As a side note, > > It appears that the diaphragm life on this petcock is ~25Kmiles +/-. > > The previous petcock diaphragm failed to external leak at ~25K. The bike > now has 52K and has been stumbling the last 5K at temps above 90F; > annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary > a stumble and often drinks from the same pump/hose. > > Go figure. > > A complete OEM rebuild kit (as I recall) is ~$30. Includes all the > moving parts and O-rings. > The alternate fix to all this is a $20 manual petcock block off plate > that Jeff Saline makes. > I have that part in my pocket, and will make that change if necessary. > > Another item of note, > examine the plate that contains the vacuum nipple. > It has two holes on the inside to the plate. > The center hole must be able to 'draw' vacuum easily; that is what makes > the petcock flow fuel. > > Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny > amount of air when you blow into the vacuum nipple; that lets the > pressure off the petcock when the engine is shutoff. > > Jeff Saline and I checked a couple of these backing plates from our > 'bone-pile' and some did not flow air. > > Does your bike stumble? > Is it the diaphragm? > You just won't know until you tear it down and look at it. > > Pay close attention to the parts orientation as you tear down the > petcock...there is a little spring under the outer plate that is just > dying to jump off your bench and run across the room and fall into a > deep crack. cough. > > Launching on Wednesday for 3Ksmiles; right into the teeth of a South > Dakota-Iowa-Missouri heatwave. Will know for double dog sure on > Wednesday afternoon if this IS the cure. smile. > > revmaaatin. > > > > No virus found in this message. > Checked by AVG - www.avg.com http://www.avg.com> > Version: 2012.0.2242 / Virus Database: 3211/6110 - Release Date: 08/26/13 >

[revmaaatin]

I would say, we are 'richly' in heated agreement. I just hope I got it cured. I fully expect it to be so. m.

--- In DSN_KLR650@yahoogroups.com, Jeff Khoury wrote: > > Stumbling when hot is almost always a symptom of being too rich. Now the cause could be many things, but it is almost invariably a mixture problem. > > -Jeff Khoury > > > ----- Original Message ----- > From: "revmaaatin" > To: "DSN KLR650" DSN_KLR650@yahoogroups.com> > Sent: Monday, August 26, 2013 4:53:46 PM > Subject: [DSN_KLR650] When it is HOT, she stubles. > > > > > > > Finally, I think I got the bike to stop stumbling. > > Jeff Saline and I have been chasing this phantom for over 3, tiring years (at least tiring for me) > > 3 years ago the 1998 KLR650 presented with a problem that only manifested itself with 90F+ temps that seemed like the bike was running out of gas...except when you went to reserve of 'enricher-full' position, it did not get better. At the worst case, > > The bike would barely pull itself at 35mph if the temps were above 90F; a tedious proposition at best. > > I was pretty sure it was a fuel delivery problem; but what? > > I drained the fuel bowl. > > I wrapped the fuel line with foil bubble wrap > > I changed fuel brands > > I Seafoam-ed treatment of the fuel in the tank until the stock price went up... > > Jeff Saline tore down the gas cap (it had sticking valves) > > I went to premium gas > > Made sure it was not ethanol gas. Again. > > changed the spark plug > > Tore down the gas cap again: rubber valves not perfect but flowed air. > > I changed the gas cap in June to a brand new gas cap from my bone pile. > > Stumbled along as soon as it hit the 90F+ again; so I changed back to the old gas cap. > > Then, changed the vacuum line to the petcock > > checked the float bowl fuel level > > serviced the air cleaner. > > all the while, > > each correction was a tedious process as we don't have a lot of consecutive 90F days...so make a change and then wait for the next hot day. > > It could be weeks! Sometimes months. > > shrug. > > = the temp would decrease and not have a problem for 100s of miles. shrug. > > But the dog days of summer are upon us, so we got some hot days ahead. > > Riding 10 days ago near Williston North Dakota, we were bumping 90F and the bike began to stumble again. sigh. > At least I know it is not solved. cough. > > So fast forward to last, Saturday--the wx forecast is HOT. > > Like to hot for the Cat on a tin roof, hot > > To Hot to fish. > > To Hot for most Harley riders, hot. > > you get the picture.... > > After much knashing of teeth, and process of elimination, > > I (convinced myself) was being very methodical about the checking process as I wanted to know, what the actual item that was the ultimate fix. > > = only one item at a time changed, > > then verify: > > it appears/and verified at this time the only item remaining has to be a bad petcock diaphragm. > > So, I got busy and pulled the tank, > > tore down to petcock; (best done with the tank off, least you drown your work area with petrol.) > > During the p/c teardown, the diaphragm was wet on both sides of the diaphragm, which indicates (to me) extra fuel was being sucked into the intake and 'drowning' the bike vs. starving the bike. > > at least that is my present understanding...that the fuel was only supposed to be on one side of the double diaphragm. > > Fortunately, I possessed a new petcock diaphragm (takeoff part) purchased from the F 1 builders of the USMC diesel bikes. > > 70 plus miles of spirited riding today at 90F+ and nary a stumble. > I am pleased, to say the least. > > As a side note, > > It appears that the diaphragm life on this petcock is ~25Kmiles +/-. > > The previous petcock diaphragm failed to external leak at ~25K. The bike now has 52K and has been stumbling the last 5K at temps above 90F; > annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary a stumble and often drinks from the same pump/hose. > > Go figure. > > A complete OEM rebuild kit (as I recall) is ~$30. Includes all the moving parts and O-rings. > The alternate fix to all this is a $20 manual petcock block off plate that Jeff Saline makes. > I have that part in my pocket, and will make that change if necessary. > > Another item of note, > examine the plate that contains the vacuum nipple. > It has two holes on the inside to the plate. > The center hole must be able to 'draw' vacuum easily; that is what makes the petcock flow fuel. > > Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny amount of air when you blow into the vacuum nipple; that lets the pressure off the petcock when the engine is shutoff. > > Jeff Saline and I checked a couple of these backing plates from our 'bone-pile' and some did not flow air. > > Does your bike stumble? > Is it the diaphragm? > You just won't know until you tear it down and look at it. > > Pay close attention to the parts orientation as you tear down the petcock...there is a little spring under the outer plate that is just dying to jump off your bench and run across the room and fall into a deep crack. cough. > > Launching on Wednesday for 3Ksmiles; right into the teeth of a South Dakota-Iowa-Missouri heatwave. Will know for double dog sure on Wednesday afternoon if this IS the cure. smile. > > revmaaatin. >

[Desert Datsuns]

Nevermind, I see you resolved the problem. With all the breaks in the story apparently I thought I was at the end, where there was another 15 lines to go. Ryan Phoenix, AZ revmaaatin wrote:

> > > Finally, I think I got the bike to stop stumbling. > > Jeff Saline and I have been chasing this phantom for over 3, tiring > years (at least tiring for me) > > 3 years ago the 1998 KLR650 presented with a problem that only > manifested itself with 90F+ temps that seemed like the bike was running > out of gas...except when you went to reserve of 'enricher-full' > position, it did not get better. At the worst case, > > The bike would barely pull itself at 35mph if the temps were above 90F; > a tedious proposition at best. > > I was pretty sure it was a fuel delivery problem; but what? > > I drained the fuel bowl. > > I wrapped the fuel line with foil bubble wrap > > I changed fuel brands > > I Seafoam-ed treatment of the fuel in the tank until the stock price > went up... > > Jeff Saline tore down the gas cap (it had sticking valves) > > I went to premium gas > > Made sure it was not ethanol gas. Again. > > changed the spark plug > > Tore down the gas cap again: rubber valves not perfect but flowed air. > > I changed the gas cap in June to a brand new gas cap from my bone pile. > > Stumbled along as soon as it hit the 90F+ again; so I changed back to > the old gas cap. > > Then, changed the vacuum line to the petcock > > checked the float bowl fuel level > > serviced the air cleaner. > > all the while, > > each correction was a tedious process as we don't have a lot of > consecutive 90F days...so make a change and then wait for the next hot day. > > It could be weeks! Sometimes months. > > shrug. > > = the temp would decrease and not have a problem for 100s of miles. shrug. > > But the dog days of summer are upon us, so we got some hot days ahead. > > Riding 10 days ago near Williston North Dakota, we were bumping 90F and > the bike began to stumble again. sigh. > At least I know it is not solved. cough. > > So fast forward to last, Saturday--the wx forecast is HOT. > > Like to hot for the Cat on a tin roof, hot > > To Hot to fish. > > To Hot for most Harley riders, hot. > > you get the picture.... > > After much knashing of teeth, and process of elimination, > > I (convinced myself) was being very methodical about the checking > process as I wanted to know, what the actual item that was the ultimate > fix. > > = only one item at a time changed, > > then verify: > > it appears/and verified at this time the only item remaining has to be a > bad petcock diaphragm. > > So, I got busy and pulled the tank, > > tore down to petcock; (best done with the tank off, least you drown your > work area with petrol.) > > During the p/c teardown, the diaphragm was wet on both sides of the > diaphragm, which indicates (to me) extra fuel was being sucked into the > intake and 'drowning' the bike vs. starving the bike. > > at least that is my present understanding...that the fuel was only > supposed to be on one side of the double diaphragm. > > Fortunately, I possessed a new petcock diaphragm (takeoff part) > purchased from the F 1 builders of the USMC diesel bikes. > > 70 plus miles of spirited riding today at 90F+ and nary a stumble. > I am pleased, to say the least. > > As a side note, > > It appears that the diaphragm life on this petcock is ~25Kmiles +/-. > > The previous petcock diaphragm failed to external leak at ~25K. The bike > now has 52K and has been stumbling the last 5K at temps above 90F; > annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary > a stumble and often drinks from the same pump/hose. > > Go figure. > > A complete OEM rebuild kit (as I recall) is ~$30. Includes all the > moving parts and O-rings. > The alternate fix to all this is a $20 manual petcock block off plate > that Jeff Saline makes. > I have that part in my pocket, and will make that change if necessary. > > Another item of note, > examine the plate that contains the vacuum nipple. > It has two holes on the inside to the plate. > The center hole must be able to 'draw' vacuum easily; that is what makes > the petcock flow fuel. > > Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny > amount of air when you blow into the vacuum nipple; that lets the > pressure off the petcock when the engine is shutoff. > > Jeff Saline and I checked a couple of these backing plates from our > 'bone-pile' and some did not flow air. > > Does your bike stumble? > Is it the diaphragm? > You just won't know until you tear it down and look at it. > > Pay close attention to the parts orientation as you tear down the > petcock...there is a little spring under the outer plate that is just > dying to jump off your bench and run across the room and fall into a > deep crack. cough. > > Launching on Wednesday for 3Ksmiles; right into the teeth of a South > Dakota-Iowa-Missouri heatwave. Will know for double dog sure on > Wednesday afternoon if this IS the cure. smile. > > revmaaatin. > > > > No virus found in this message. > Checked by AVG - www.avg.com http://www.avg.com> > Version: 2012.0.2242 / Virus Database: 3211/6110 - Release Date: 08/26/13 >

[revmaaatin]

Yahoo truncates at the most inopportune time. I condensed the lines as much as possible...till I vapor locked. cough. m.

--- In DSN_KLR650@yahoogroups.com, Desert Datsuns wrote: > > Nevermind, I see you resolved the problem. With all the breaks in the > story apparently I thought I was at the end, where there was another 15 > lines to go. > Ryan > Phoenix, AZ > > > revmaaatin wrote: > > > > > > Finally, I think I got the bike to stop stumbling. > > > > Jeff Saline and I have been chasing this phantom for over 3, tiring > > years (at least tiring for me) > > > > 3 years ago the 1998 KLR650 presented with a problem that only > > manifested itself with 90F+ temps that seemed like the bike was running > > out of gas...except when you went to reserve of 'enricher-full' > > position, it did not get better. At the worst case, > > > > The bike would barely pull itself at 35mph if the temps were above 90F; > > a tedious proposition at best. > > > > I was pretty sure it was a fuel delivery problem; but what? > > > > I drained the fuel bowl. > > > > I wrapped the fuel line with foil bubble wrap > > > > I changed fuel brands > > > > I Seafoam-ed treatment of the fuel in the tank until the stock price > > went up... > > > > Jeff Saline tore down the gas cap (it had sticking valves) > > > > I went to premium gas > > > > Made sure it was not ethanol gas. Again. > > > > changed the spark plug > > > > Tore down the gas cap again: rubber valves not perfect but flowed air. > > > > I changed the gas cap in June to a brand new gas cap from my bone pile. > > > > Stumbled along as soon as it hit the 90F+ again; so I changed back to > > the old gas cap. > > > > Then, changed the vacuum line to the petcock > > > > checked the float bowl fuel level > > > > serviced the air cleaner. > > > > all the while, > > > > each correction was a tedious process as we don't have a lot of > > consecutive 90F days...so make a change and then wait for the next hot day. > > > > It could be weeks! Sometimes months. > > > > shrug. > > > > = the temp would decrease and not have a problem for 100s of miles. shrug. > > > > But the dog days of summer are upon us, so we got some hot days ahead. > > > > Riding 10 days ago near Williston North Dakota, we were bumping 90F and > > the bike began to stumble again. sigh. > > At least I know it is not solved. cough. > > > > So fast forward to last, Saturday--the wx forecast is HOT. > > > > Like to hot for the Cat on a tin roof, hot > > > > To Hot to fish. > > > > To Hot for most Harley riders, hot. > > > > you get the picture.... > > > > After much knashing of teeth, and process of elimination, > > > > I (convinced myself) was being very methodical about the checking > > process as I wanted to know, what the actual item that was the ultimate > > fix. > > > > = only one item at a time changed, > > > > then verify: > > > > it appears/and verified at this time the only item remaining has to be a > > bad petcock diaphragm. > > > > So, I got busy and pulled the tank, > > > > tore down to petcock; (best done with the tank off, least you drown your > > work area with petrol.) > > > > During the p/c teardown, the diaphragm was wet on both sides of the > > diaphragm, which indicates (to me) extra fuel was being sucked into the > > intake and 'drowning' the bike vs. starving the bike. > > > > at least that is my present understanding...that the fuel was only > > supposed to be on one side of the double diaphragm. > > > > Fortunately, I possessed a new petcock diaphragm (takeoff part) > > purchased from the F 1 builders of the USMC diesel bikes. > > > > 70 plus miles of spirited riding today at 90F+ and nary a stumble. > > I am pleased, to say the least. > > > > As a side note, > > > > It appears that the diaphragm life on this petcock is ~25Kmiles +/-. > > > > The previous petcock diaphragm failed to external leak at ~25K. The bike > > now has 52K and has been stumbling the last 5K at temps above 90F; > > annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary > > a stumble and often drinks from the same pump/hose. > > > > Go figure. > > > > A complete OEM rebuild kit (as I recall) is ~$30. Includes all the > > moving parts and O-rings. > > The alternate fix to all this is a $20 manual petcock block off plate > > that Jeff Saline makes. > > I have that part in my pocket, and will make that change if necessary. > > > > Another item of note, > > examine the plate that contains the vacuum nipple. > > It has two holes on the inside to the plate. > > The center hole must be able to 'draw' vacuum easily; that is what makes > > the petcock flow fuel. > > > > Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny > > amount of air when you blow into the vacuum nipple; that lets the > > pressure off the petcock when the engine is shutoff. > > > > Jeff Saline and I checked a couple of these backing plates from our > > 'bone-pile' and some did not flow air. > > > > Does your bike stumble? > > Is it the diaphragm? > > You just won't know until you tear it down and look at it. > > > > Pay close attention to the parts orientation as you tear down the > > petcock...there is a little spring under the outer plate that is just > > dying to jump off your bench and run across the room and fall into a > > deep crack. cough. > > > > Launching on Wednesday for 3Ksmiles; right into the teeth of a South > > Dakota-Iowa-Missouri heatwave. Will know for double dog sure on > > Wednesday afternoon if this IS the cure. smile. > > > > revmaaatin. > > > > > > > > No virus found in this message. > > Checked by AVG - www.avg.com http://www.avg.com> > > Version: 2012.0.2242 / Virus Database: 3211/6110 - Release Date: 08/26/13 > > >

[achesley43@ymail.com]

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote:

> > Finally, I think I got the bike to stop stumbling. >

Thanks for the heads up. I had never though of that problem solver. Next time I pull the tank, I'm gonna check that dude. I've been having a slight stumble at steady speed for the pass two years and have been though the carb and electrics. Andy in Louisiana

[revmaaatin]

An update to my own post about high OAT stumbling- Just back from a test ride before I do the final loading of the mule. 96F (car at the gas station on board temp) 20 miles at 5500rpm. 75mph/GPS nary a stumble. I am stoked. revmaaatin

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote: > > Finally, I think I got the bike to stop stumbling. > > Jeff Saline and I have been chasing this phantom for over 3, tiring years (at least tiring for me) > > 3 years ago the 1998 KLR650 presented with a problem that only manifested itself with 90F+ temps that seemed like the bike was running out of gas...except when you went to reserve of 'enricher-full' position, it did not get better. At the worst case, > > The bike would barely pull itself at 35mph if the temps were above 90F; a tedious proposition at best. > > > I was pretty sure it was a fuel delivery problem; but what? > > > I drained the fuel bowl. > > I wrapped the fuel line with foil bubble wrap > > I changed fuel brands > > I Seafoam-ed treatment of the fuel in the tank until the stock price went up... > > > Jeff Saline tore down the gas cap (it had sticking valves) > > I went to premium gas > > Made sure it was not ethanol gas. Again. > > > changed the spark plug > > Tore down the gas cap again: rubber valves not perfect but flowed air. > > I changed the gas cap in June to a brand new gas cap from my bone pile. > > Stumbled along as soon as it hit the 90F+ again; so I changed back to the old gas cap. > > Then, changed the vacuum line to the petcock > > checked the float bowl fuel level > > serviced the air cleaner. > > all the while, > > each correction was a tedious process as we don't have a lot of consecutive 90F days...so make a change and then wait for the next hot day. > > It could be weeks! Sometimes months. > > shrug. > > = the temp would decrease and not have a problem for 100s of miles. shrug. > > > But the dog days of summer are upon us, so we got some hot days ahead. > > Riding 10 days ago near Williston North Dakota, we were bumping 90F and the bike began to stumble again. sigh. > At least I know it is not solved. cough. > > > So fast forward to last, Saturday--the wx forecast is HOT. > > Like to hot for the Cat on a tin roof, hot > > To Hot to fish. > > To Hot for most Harley riders, hot. > > you get the picture.... > > > > After much knashing of teeth, and process of elimination, > > I (convinced myself) was being very methodical about the checking process as I wanted to know, what the actual item that was the ultimate fix. > > = only one item at a time changed, > > then verify: > > it appears/and verified at this time the only item remaining has to be a bad petcock diaphragm. > > > So, I got busy and pulled the tank, > > tore down to petcock; (best done with the tank off, least you drown your work area with petrol.) > > > During the p/c teardown, the diaphragm was wet on both sides of the diaphragm, which indicates (to me) extra fuel was being sucked into the intake and 'drowning' the bike vs. starving the bike. > > at least that is my present understanding...that the fuel was only supposed to be on one side of the double diaphragm. > > > Fortunately, I possessed a new petcock diaphragm (takeoff part) purchased from the F 1 builders of the USMC diesel bikes. > > > 70 plus miles of spirited riding today at 90F+ and nary a stumble. > I am pleased, to say the least. > > > As a side note, > > It appears that the diaphragm life on this petcock is ~25Kmiles +/-. > > The previous petcock diaphragm failed to external leak at ~25K. The bike now has 52K and has been stumbling the last 5K at temps above 90F; > annoying in view that the 'sister' 36Kmilr KLR650 in the garage has nary a stumble and often drinks from the same pump/hose. > > Go figure. > > > A complete OEM rebuild kit (as I recall) is ~$30. Includes all the moving parts and O-rings. > The alternate fix to all this is a $20 manual petcock block off plate that Jeff Saline makes. > I have that part in my pocket, and will make that change if necessary. > > > Another item of note, > examine the plate that contains the vacuum nipple. > It has two holes on the inside to the plate. > The center hole must be able to 'draw' vacuum easily; that is what makes the petcock flow fuel. > > Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny amount of air when you blow into the vacuum nipple; that lets the pressure off the petcock when the engine is shutoff. > > > Jeff Saline and I checked a couple of these backing plates from our 'bone-pile' and some did not flow air. > > > Does your bike stumble? > Is it the diaphragm? > You just won't know until you tear it down and look at it. > > > Pay close attention to the parts orientation as you tear down the petcock...there is a little spring under the outer plate that is just dying to jump off your bench and run across the room and fall into a deep crack. cough. > > Launching on Wednesday for 3Ksmiles; right into the teeth of a South Dakota-Iowa-Missouri heatwave. Will know for double dog sure on Wednesday afternoon if this IS the cure. smile. > > > revmaaatin. >

[Jeff Saline]

On Tue, 27 Aug 2013 19:27:00 -0400 klrdon writes:

> Hi all, > Q 1 - Just installed 1" lowering links on 02 KLR. Does chain > adjustment > need to be changed? Thought is, no. Tight spot which we adjust for > is > still the same. > > Q 2 - What chemical is good to remove powder coat paint. Need to > weld a > crack in a Happy Trails engine guard that runs along the original > weld. > Any thoughts on preventing a crack along the side of the new weld? > > Best to all! > > Regards, > Don M > Atlanta, GA

<><><><><><> <><><><><><> Don, I'll say no on the chain adjustment since the geometry is the same for the chain. For the crack I'll say don't remove the paint with chemicals but instead use a grinder. That will remove paint and can also shape the repair area so it is ready to weld. Wipe clean with acetone and then weld. I'm not familiar with the Happy Trails products but TIG welding will probably be the best process for controlling the HAZ (heat affected zone). Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . ____________________________________________________________ One Weird Trick Could add $1,000s to Your Social Security Checks! See if you Qualify… http://thirdpartyoffers.juno.com/TGL3141/521d377216ef8377140e2st01vuc

[RobertWichert]

Yahoo! Way to go Rev! Robert ========================================

On 8/27/2013 3:10 PM, revmaaatin wrote: > > An update to my own post about high OAT stumbling- > > Just back from a test ride before I do the final loading of the mule. > 96F (car at the gas station on board temp) > 20 miles at 5500rpm. 75mph/GPS > nary a stumble. > I am stoked. > > revmaaatin > > --- In DSN_KLR650@yahoogroups.com > , "revmaaatin" wrote: > > > > Finally, I think I got the bike to stop stumbling. > > > > Jeff Saline and I have been chasing this phantom for over 3, tiring > years (at least tiring for me) > > > > 3 years ago the 1998 KLR650 presented with a problem that only > manifested itself with 90F+ temps that seemed like the bike was > running out of gas...except when you went to reserve of > 'enricher-full' position, it did not get better. At the worst case, > > > > The bike would barely pull itself at 35mph if the temps were above > 90F; a tedious proposition at best. > > > > > > I was pretty sure it was a fuel delivery problem; but what? > > > > > > I drained the fuel bowl. > > > > I wrapped the fuel line with foil bubble wrap > > > > I changed fuel brands > > > > I Seafoam-ed treatment of the fuel in the tank until the stock price > went up... > > > > > > Jeff Saline tore down the gas cap (it had sticking valves) > > > > I went to premium gas > > > > Made sure it was not ethanol gas. Again. > > > > > > changed the spark plug > > > > Tore down the gas cap again: rubber valves not perfect but flowed air. > > > > I changed the gas cap in June to a brand new gas cap from my bone pile. > > > > Stumbled along as soon as it hit the 90F+ again; so I changed back > to the old gas cap. > > > > Then, changed the vacuum line to the petcock > > > > checked the float bowl fuel level > > > > serviced the air cleaner. > > > > all the while, > > > > each correction was a tedious process as we don't have a lot of > consecutive 90F days...so make a change and then wait for the next hot > day. > > > > It could be weeks! Sometimes months. > > > > shrug. > > > > = the temp would decrease and not have a problem for 100s of miles. > shrug. > > > > > > But the dog days of summer are upon us, so we got some hot days ahead. > > > > Riding 10 days ago near Williston North Dakota, we were bumping 90F > and the bike began to stumble again. sigh. > > At least I know it is not solved. cough. > > > > > > So fast forward to last, Saturday--the wx forecast is HOT. > > > > Like to hot for the Cat on a tin roof, hot > > > > To Hot to fish. > > > > To Hot for most Harley riders, hot. > > > > you get the picture.... > > > > > > > > After much knashing of teeth, and process of elimination, > > > > I (convinced myself) was being very methodical about the checking > process as I wanted to know, what the actual item that was the > ultimate fix. > > > > = only one item at a time changed, > > > > then verify: > > > > it appears/and verified at this time the only item remaining has to > be a bad petcock diaphragm. > > > > > > So, I got busy and pulled the tank, > > > > tore down to petcock; (best done with the tank off, least you drown > your work area with petrol.) > > > > > > During the p/c teardown, the diaphragm was wet on both sides of the > diaphragm, which indicates (to me) extra fuel was being sucked into > the intake and 'drowning' the bike vs. starving the bike. > > > > at least that is my present understanding...that the fuel was only > supposed to be on one side of the double diaphragm. > > > > > > Fortunately, I possessed a new petcock diaphragm (takeoff part) > purchased from the F 1 builders of the USMC diesel bikes. > > > > > > 70 plus miles of spirited riding today at 90F+ and nary a stumble. > > I am pleased, to say the least. > > > > > > As a side note, > > > > It appears that the diaphragm life on this petcock is ~25Kmiles +/-. > > > > The previous petcock diaphragm failed to external leak at ~25K. The > bike now has 52K and has been stumbling the last 5K at temps above 90F; > > annoying in view that the 'sister' 36Kmilr KLR650 in the garage has > nary a stumble and often drinks from the same pump/hose. > > > > Go figure. > > > > > > A complete OEM rebuild kit (as I recall) is ~$30. Includes all the > moving parts and O-rings. > > The alternate fix to all this is a $20 manual petcock block off > plate that Jeff Saline makes. > > I have that part in my pocket, and will make that change if necessary. > > > > > > Another item of note, > > examine the plate that contains the vacuum nipple. > > It has two holes on the inside to the plate. > > The center hole must be able to 'draw' vacuum easily; that is what > makes the petcock flow fuel. > > > > Then there is the tiny, tiny, tiny hole must flow a tiny, tiny, tiny > amount of air when you blow into the vacuum nipple; that lets the > pressure off the petcock when the engine is shutoff. > > > > > > Jeff Saline and I checked a couple of these backing plates from our > 'bone-pile' and some did not flow air. > > > > > > Does your bike stumble? > > Is it the diaphragm? > > You just won't know until you tear it down and look at it. > > > > > > Pay close attention to the parts orientation as you tear down the > petcock...there is a little spring under the outer plate that is just > dying to jump off your bench and run across the room and fall into a > deep crack. cough. > > > > Launching on Wednesday for 3Ksmiles; right into the teeth of a South > Dakota-Iowa-Missouri heatwave. Will know for double dog sure on > Wednesday afternoon if this IS the cure. smile. > > > > > > revmaaatin. > > > > -- Robert P Wichert P.Eng. Inc. LEED AP, HERS II, CEA +1 916 966 9060 FAX +1 916 966 9068 [Non-text portions of this message have been removed]