[dsn_klr650] 3rd doohickey upgrade

[myclaydaddy]

So I have a question for the group; I was riding over the weekend on my '08 KLR 650 when it decided it no longer wanted to be as reliable as before. As I was riding down the freeway the bike suddenly just died, no warning, no sputtering just died. As I am fairly inept mechanically, I took to figuring out what had happened. Electrics were totally fine, it turned over no problem but would not start. Then, magically, it started up fine and ran perfectly for quite a while until it did the same thing again, twice more! Going off road that same day could not reproduce the problem. Long story short, I concluded it definitely is a fuel delivery problem but I can't figure out where or how. The vacuum line to the petcock is intact, so what am I missing? I popped the gas cap open to help the overflow vent line but I don't think that did anything special although it hasn't done it again since. Any suggestions? Thanks-

[Darren Clark]

Sounds like the vent hose is plugged or pinched. What that will do is create a vacuum in the gas tank when the fuel drains into the carb, then with enough vacuum the fuel will not drain into the carb anymore. As air leaks into the tank (maybe through the hose or somewhere else) fuel will start to slowly leak into the carb again. Check your hoses, they plug up in my bike a lot. myclaydaddy wrote:

> So I have a question for the group; I was riding over the weekend on my '08 KLR 650 when it decided it no longer wanted to be as reliable as before. As I was riding down the freeway the bike suddenly just died, no warning, no sputtering just died. As I am fairly inept mechanically, I took to figuring out what had happened. Electrics were totally fine, it turned over no problem but would not start. Then, magically, it started up fine and ran perfectly for quite a while until it did the same thing again, twice more! Going off road that same day could not reproduce the problem. > Long story short, I concluded it definitely is a fuel delivery problem but I can't figure out where or how. The vacuum line to the petcock is intact, so what am I missing? I popped the gas cap open to help the overflow vent line but I don't think that did anything special although it hasn't done it again since. Any suggestions? Thanks- > > > > > ------------------------------------ > > 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/dsnklr650Yahoo! Groups Links > > > > >

-- Darren Clark http://www.flickr.com/photos/84373829@N00/ 2004 KLR-650 Fowlerville, MI [Non-text portions of this message have been removed]

[Michael Martin]

Your description as to the engine suddenly dying with no warning indicates to me an ignition problem rather than a fuel problem. Has your bike had the work done on it for the wiring harness recall? http://www.usrecallnews.com/2009/02/nhtsa-4321.html Mike Martin, Louisville, KY ________________________________ From: myclaydaddy To: DSN_KLR650@yahoogroups.com Sent: Monday, October 5, 2009 10:46:39 PM Subject: [DSN_KLR650] Unexpected failure So I have a question for the group; I was riding over the weekend on my '08 KLR 650 when it decided it no longer wanted to be as reliable as before. As I was riding down the freeway the bike suddenly just died, no warning, no sputtering just died. [Non-text portions of this message have been removed]

[Jeff Saline]

On Tue, 06 Oct 2009 02:46:39 -0000 "myclaydaddy" writes:

> So I have a question for the group; I was riding over the weekend on > my '08 KLR 650 when it decided it no longer wanted to be as reliable > as before. As I was riding down the freeway the bike suddenly just > died, no warning, no sputtering just died. As I am fairly inept > mechanically, I took to figuring out what had happened. Electrics > were totally fine, it turned over no problem but would not start. > Then, magically, it started up fine and ran perfectly for quite a > while until it did the same thing again, twice more! Going off road > that same day could not reproduce the problem. > Long story short, I concluded it definitely is a fuel delivery > problem but I can't figure out where or how. The vacuum line to the > petcock is intact, so what am I missing? I popped the gas cap open > to help the overflow vent line but I don't think that did anything > special although it hasn't done it again since. Any suggestions? > Thanks-

<><><><><><> <><><><><><> myclaydaddy, I think your fuel problem is electrical. : ) You don't mention if the recall for the wiring harness has been taken care of. If so then maybe it's something else but... no sputtering says to me it's not fuel and is electrical. Kind of like turning the key to the off position. The engine just stops. Take it for a ride and turn the fuel off. Do that in a low traffic area where coming to an unexpected stop won't endanger you or others. Then see how a fuel delivery problem acts. Electrical and fuel delivery issues exhibit quite different symptoms. If you aren't comfortable around the electrical system and getting to it the dealer should be able to take a look for you. I understand the electrical is for the main wiring harness rubbing through up near the steering head. I also understand you have to pull the fuel tank to check it out and may have to really dig to find the abraded wires. Good luck, 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, 79 R100RT . ____________________________________________________________ Photography The Art Institutes. Get info on the photography program. http://thirdpartyoffers.juno.com/TGL2141/c?cp=Pla0bW5UZ0_sPEl33urxaQAAJ1DWfJIDP-R0_NC3mMpGFS0kAAQAAAAFAAAAAN9PTT4AAAMlAAAAAAAAAAAAAAAAAAhBJwAAAAA=

[Greg May]

By the sound of it I would have to guess that your problem is electrical since it dies so quickly. The wiring harness problem apparently causes this if you haven't had it checked/repaired yet but the other suspect I would check would be the sidestand switch, mine has never caused any problems but will kill the engine dead if you let the clutch out with the sidestand down and from what I read are prone to fail.....Have a great day.....Greg

--- On Mon, 10/5/09, myclaydaddy wrote: From: myclaydaddy Subject: [DSN_KLR650] Unexpected failure To: DSN_KLR650@yahoogroups.com Received: Monday, October 5, 2009, 11:46 PM So I have a question for the group; I was riding over the weekend on my '08 KLR 650 when it decided it no longer wanted to be as reliable as before. As I was riding down the freeway the bike suddenly just died, no warning, no sputtering just died. As I am fairly inept mechanically, I took to figuring out what had happened. Electrics were totally fine, it turned over no problem but would not start. Then, magically, it started up fine and ran perfectly for quite a while until it did the same thing again, twice more! Going off road that same day could not reproduce the problem. Long story short, I concluded it definitely is a fuel delivery problem but I can't figure out where or how. The vacuum line to the petcock is intact, so what am I missing? I popped the gas cap open to help the overflow vent line but I don't think that did anything special although it hasn't done it again since. Any suggestions? Thanks- __________________________________________________________________ Looking for the perfect gift? Give the gift of Flickr! http://www.flickr.com/gift/ [Non-text portions of this message have been removed]

[The Reverend]

I doubt it's fuel. IT would sputter and not die suddenly. Oddly enough, my bike did the same thing on the fwy last week. Suddenly a complete death. Coasted to the shoulder and cranked with no start. Fuel flowed (I have a clear filter and it had plenty of fuel and it sloshed when I cranked). Two minutes later the bike started and ran fine. No issue since. I suspect the little wire from the battery that I had to lengthen when I installed the AGM battery. If that came off, that could cause issues like that. -----Original Message----- From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of myclaydaddy So I have a question for the group; I was riding over the weekend on my '08 KLR 650 when it decided it no longer wanted to be as reliable as before. As I was riding down the freeway the bike suddenly just died, no warning, no sputtering just died. As I am fairly inept mechanically, I took to figuring out what had happened. Electrics were totally fine, it turned over no problem but would not start. Then, magically, it started up fine and ran perfectly for quite a while until it did the same thing again, twice more! Going off road that same day could not reproduce the problem. Long story short, I concluded it definitely is a fuel delivery problem but I can't figure out where or how. The vacuum line to the petcock is intact, so what am I missing? I popped the gas cap open to help the overflow vent line but I don't think that did anything special although it hasn't done it again since. Any suggestions?

[Charlie Y]

Thanks Ed.

----- Original Message ----- From: To: "Charlie Y" Sent: Thursday, October 08, 2009 12:21 AM Subject: Re: [DSN_KLR650] 3rd Doohickey Upgrade > Hi Charlie! > > Insomniac eddie here. The drilling is done on the case where the anchor > end > of the torsion spring is held. > The other end of the spring just hooks in the end of the doohickey's arc > shaped slot. > On my Eagle Mike kit, the spring anchor hole called-for was at > approximately 6:30-7 o'clock as you would view the doohickey shaft > dead on. If I had it to do over, I'd make two holes while I was drilling. > One at the prescribed location and another around 4:30-5 o'clock > and have it ready in case the first hole proved to make installing the > spring a way-tight challenge. > > If the bolts on your bike came out with clean threads, that is to say - no > evidence of a thread locking agent from the factory - > I wouldn't put any on them going back together. Remember the torque values > for those bolts is a lot lower than one > might accurately "feel", too. In lieu of locking agent, a small-small dab > of rtv silicone on the bolts couldn't hurt. > It'd be kinder to the alloy threads in the case, too. > > Take your time and don't forget there's a 8mm bolt "hiding " behind where > the starter gears go. > I couldn't figure out why the inner cover on my bike was "stuck" and > wouldn't come off. Then I saw the bolt - right > there in the middle and wanted to kick myself. > > Have fun and let us know how it goes! > > eddie > 08' GL1800 > 09' KLR650 > >> [Original Message] >> From: Charlie Y >> To: DSN_KLR650@yahoogroups.com> >> Date: 10/7/2009 11:01:09 PM >> Subject: Re: [DSN_KLR650] 3rd Doohickey Upgrade >> >> OK the "clatter" has gotten to be unbearable at certain RPM's >> on my KLR with 5200 miles. So I started getting the parts and tools I > need >> together. >> >> You had to drill the new do to hold the torsion spring? >> And... >> Tell me what did you do? Do you put anti-seize on the 10 inner and outer >> case >> bolts OR loctite or anything? The instructions I got don't say aything > about >> that. >> >> -- charlie >> >> ----- Original Message ----- >> From: "spike55_bmw" >> To: DSN_KLR650@yahoogroups.com> >> Sent: Tuesday, October 06, 2009 1:56 PM >> Subject: [DSN_KLR650] 3rd Doohickey Upgrade >> >> >> > It's official, installed my 3rd upgrade >> >> >> >> ------------------------------------ >> >> 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/dsnklr650Yahoo! Groups Links >> >> >> > > >