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Old 12-05-2017, 08:19 AM   #1
Jeremy_283
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Default Bike Just Starts Cutting Out (Strange)

Seems to only occur in HOT or COLD weather while either on 20+ minute interstate runs or after being on the trails moving slow for a while.

The bike will be going good (like yesterday) then all of a sudden like a switch was flipped it will cut out. It is difficult to get above 35mph and while it cuts out at lower RPMs at 4,000rpm and above the cutting out is more pronounced (at any speed, at any throttle position, at any throttle load). If at a lower RPM and I turn the throttle fully it will cut out too. I can ride around town for 30 minutes and it'll never occur. If I let the bike sit overnight it's good for riding the next morning but if I let it sit for an hour it's not any better an hour later.

Air filter is clean, valves in spec. Fresh gas. No recent changes to the bike.

Thoughts?

Last edited by Jeremy_283; 12-05-2017 at 08:24 AM.
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Old 12-05-2017, 09:33 AM   #2
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Default Re: Bike Just Starts Cutting Out (Strange)

I would bypass the clutch and kick stand safety switches and see if that helped.
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Old 12-05-2017, 11:07 AM   #3
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Default Re: Bike Just Starts Cutting Out (Strange)

yep, sidestand and clutch safety switches first, then check the gas tank vent (run with the cap open to see if that fixes the problem), next up; vacuum petcock diaphragm failure. ....you don't have an aftermarket inline filter do you?

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Old 12-07-2017, 04:48 PM   #4
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Default Re: Bike Just Starts Cutting Out (Strange)

Quote:
Originally Posted by DPelletier View Post
yep, sidestand and clutch safety switches first, then check the gas tank vent (run with the cap open to see if that fixes the problem), next up; vacuum petcock diaphragm failure. ....you don't have an aftermarket inline filter do you?

Dave
No in line filter. Kickstand switch made no difference nor does the gas cap. I could ride around town all day but it 5,000 rpm highway runs for 20+ minutes or slow trails is where the issues arise.
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Old 12-07-2017, 05:16 PM   #5
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Default Re: Bike Just Starts Cutting Out (Strange)

there go the easy ones! ...maybe heat related....is the gauge showing hot when it does it? does your fan function and come on?

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Old 12-07-2017, 05:19 PM   #6
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Default Re: Bike Just Starts Cutting Out (Strange)

the combination of when it occurs is strange; fuel delivery issues that would affect a bike after a sustained high speed run wouldn't manifest in low speed trails and likewise, a wiring harness rub through issue that could easily be triggered on low speed trails shouldn't happen going straight on the highway. Nonetheless, check the carb inlet screens in the tank for debris and it can't hurt to remove the tank and check the harness.

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Old 12-07-2017, 07:01 PM   #7
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Default Re: Bike Just Starts Cutting Out (Strange)

What year KLR650? Gen I and Gen II have some important differences.

What does the tachometer do when it is cutting out? Does the needle drop to zero like you turned off the key or does it follow engine rpm/road speed decrease?

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Old 12-07-2017, 07:15 PM   #8
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Default Re: Bike Just Starts Cutting Out (Strange)

The only thing those two situations seem to have in common is higher trapped heat, no? Can the carb overheat or something? The float should be cooled by the fuel, and not expand to float higher than normal, so I have no idea.
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Old 12-07-2017, 11:37 PM   #9
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Default Re: Bike Just Starts Cutting Out (Strange)

My sons bike had the same issue and it was pinholes in the diaphragm. He also had bits of rubber in the bowl from the petcock gasket as well.

The pinholes were hard to find BTW
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Old 12-08-2017, 11:57 AM   #10
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Default Re: Bike Just Starts Cutting Out (Strange)

Quote:
Originally Posted by C5dad View Post
My sons bike had the same issue and it was pinholes in the diaphragm. He also had bits of rubber in the bowl from the petcock gasket as well.

The pinholes were hard to find BTW
The carb diaphram? It sure is an odd issue. I've never had carb issues before.
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Old 12-08-2017, 12:15 PM   #11
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Default Re: Bike Just Starts Cutting Out (Strange)

J. I think that is the petcock (vacuum) diaphragm
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