won't idle

[Andy T]

Seems to me your timming is off. Being off 1 tooth will make any engine do this. Put the crank at TDC make sure your timing marks on the cams ar facing AWAY from each other, paralel to the cylinder head... -Andy dr_coady wrote: This is a long post but I am trying to cover all bases to help pinpoint the problem I am having a major problem with my bike that I can't figure out. It won't idle. I have been doing a whole lot of work on it for the past 3 months including upgrading balancer system with the new solid sprockets, new front balancer shaft bearings, new doohickey, spring, bolt. I also replaced the large starter gear the spins on the crankshaft with a used one because the "fins" on the back of mine had been mangled. Also replaced clutch cover gasket, h2o pumps oil and mechanical seals, etc. I also checked the valve clearance and timing and cleaned the carburetor while doing all the other work. I recheck the valve clearance and timing after finishing all the balancer work and sealing it back up. At some point after doing all the major work for the balancer system I took the bike for a test ride. It was rough starting, and ran a little rought, and it would idle then. It was backfiring after getting on the throttle hard and then letting if off quickly. I replaced the copper header pipe exhaust gasket, tighten the muffler to exhaust pipe clamp, plus had to take off generator cover to replace that gasket that was leaking. I also turned carb, pulled out idle screw, spring, washer (forgot about o-ring) and sprayed some cleaner and compressed air in there. Put everything back together and it wouldn't idle It would start (weakly) with choke (enricher) on but as soon as I shut choke off it would die. I then pulled carb completely, cleaned it again, and realized that idle screw o-ring was missing. I got a new o-ring from Kawasaki installed it, set idle screw to what it had been before problem started and put carb back in. Still had the same problem. I tried adjusting the idle screw both in and out (from about 1 to 3 turns out) with no effect. I tried adjusting the idle speed. It seems to do best with idle speed screw back all the way out. I pulled the carb again and cleaned it and blew air through all passages. I ran a thin wire through all passage, except the one the goes from the idle screw hole to the pilot jet hole because I couldn't get it in there. But if I plug off pilot jet hole in bowl, idle screw hole and the coasting enricher hole (under the coaster diaphragm), which i think are all the passages that use the pilot system and blow air through, it seems to blow clear through the pilot holes in the engine side of the carb I have checked and adjusted the fuel level. I have sprayed water on the carb to engine boot/holder while engine was running to try to eliminate an air leak there but nothing changed. So the bike will start with the choke/enricher on, but even with it all the way out, the engine will only get to about 3,000 rpms. As soon as I close the choke it will die. If I open the throttle with the enricher on, the engine will die. I can get it started by feathering the throttle a bit but it will die as soon as I close the throttle. And there is quite a bit of popping when it is running while feathering the throttle. I can start it with the enricher on, competely cover the air box intake, shut off the enricher and the bike will idle, but very very roughly. The bike heats up very very quickly when it is running. It seems as though the pilot/idle system is just not working at all. Or maybe I have a intake leak somewhere. The vacuum petcock hose seems okay but I haven't replaced it. Enricher cable, plunger, nut and rubber boot all seem okay. Anyone have any ideas? I have about had it. The carb has been in and out about 10 times in the past month. Any help would be appreciated. I wish I had access to a working spare carb to put in and to make find out if it is just a carb problem. Everything is stock with the carb. No mods have been done except to adjust idle screw. Exhaust is also stock as well as the airbox and air filter. The bike is a A1 with 27k on it. I have had it for 5 years. It was severly neglected when I got it. Dan Archive Quicksearch at: http://www.angelfire.com/ut/moab/klr650_data_search.html List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Member Map at: http://www.frappr.com/dsnklr650 Yahoo! Groups Links --------------------------------- How low will we go? Check out Yahoo! Messenger s low PC-to-Phone call rates. [Non-text portions of this message have been removed]