Attention amateur mechanics!
 

I've got a brand new KLR that's acting weird. It keeps stalling at low speed -- generally as I pull the clutch in and come to a stop at an intersection, or when I'm in gear (clutch in), and walking the bike backwards into or out of a parking space. When the bike idles, it seems very irregular -- you can watch it go from 1100 RPM to 1700. Playing with the idle screw didn't seem to help. I'm taking it into the shop, but I'd like to have an idea of what it might be before I go. Any suggestions?

Paul,

Some food for thought here, but we'd need more info to really offer more help.

Questions:

1. Does this happen in neutral (not just with clutch in)?
2. Does the bike start and run OK at first?
3. Is there a noticeable lack of power?
4. What's the plug look like?


Since it's a new bike, I'm guessing it might be fuel or compression related, nothing disastrous like bad rings, etc.
One thing might be compression. Improper compression on a new KLR could result from poor valve clearance. This should have been checked around the first 500mi/805km or so (every 6000 mi/9660 km after that.) Was that done? Did the dealer or local shop do it? Did you get a printout with the measurements? I would never trust a dealership to do the first 500mi
check/adjustment correctly, if at all. It seems a likely place to skimp. If it was checked and you have the numbers, was
it close to begin with? The valve clearances will tighten over time. Maybe sufficient miles have been accumulated to bring the valves out of adjustment.

How long has this been happening? After a recent fill up? Could be bad gas, drain and refill from another station if you
suspect.


What oil weight are you running? Incorrect oil viscosity could cause problems, clutch slippage too. (remember the clutch is
a wet clutch and shares oil with the engine.)


If it's brand new, and you haven't done the valve check at ~500 mi, I'd suspect that first. You can do this yourself if
you're at all handy. There's plenty of help online and even a video you can purchase to show you how. Best place for the
video, service manuals, and valve-shims is: http://www.arrowheadmotorsports.com


In case you don't know about the Yahoo KLR group, go here: http://groups.yahoo.com/group/DSN_klr650/
Best place to get technical help. If it happens to a KLR, someone on that list will know what to do.

Good luck.

Just a simple note - it COULD be something wrong with the electric either - if it's JUST the instrument showing, but not the engine getting up!

Maybe the gas-string has been laid the wrong way either - then, when turning in a very small circle, it is pulled and the engine runs up...
Or the choke...
Check that first - most times it's as simple as that (I had something alike - the choke was stuck)!
Good Luck!

Lots of food for thought here. I appreciate you guys taking the time to answer my query.

In answer to your questions:

The bike idles irregularly in neutral, but I've only had it die in neutral.

It seems to start and run well, and there is no lack of power.

The bike has been serviced properly, including the 800 km valve adjustment. But...I never thought about the dealer screwing it up. I don't know what the measurements are (or what they mean, for that matter.) I've put 4000 km on the bike since that adjustment.

I really started to notice the stalling after I had the voltage regulator replaced.

Next stop -- the dealership. I'll let you know what they say....

Sounds like the known issue of the clutch safety switch at the clutch lever, or the side stand safety switch. Go to http://www.bigcee.com/klr650faq.html
and look for the known issues section for the fix.
Hope this helps,
Conall
http://www.klr650.com

As you can read, there are many things that could be causing the problem and although I am sure we can help you, I don't think you should be having to worry about these irritations on a new bike. Have you considered polite but firm pressure on the dealer and Kawasaki for a new replacement under the terms of your warranty? Don't like to be negative, but you really shouldn't have to put up with this on a new bike. Take it back!

Here, here, John Z.

But....

If your dealer is anything like the tipical dealer around here (Midwest US) you might be better off trouble shooting it yourself. Good luck and keep up posted.

Kurt

You've got a clogged jet. http://www.horizonsunlimited.com/ubb/wink.gif
Take the carb off and blow some compressed air through the jets and that'll take care of it. While you have the bowl off, turn out the pilot screw 1.5 turns.