KLR250 stalls under load - KACR or carb?

[gilliganis]

Hi from Darwin, Australia!

I have a '99 KLR250

I'm not sure about any differences between AUS and US models, but anyhow mine is a kickstart model.

I bought this bike with about 6500km on it, I've put about the same on it over the last 2 years.

A while ago I had issues with the bike intermittently losing power (completely) and stalling, while riding. This happened after storing the bike for a while (I hadn't drained the bowl)

I pulled the carby and (to be best of my ability given my lack of experience) stripped and cleaned it.

When I ran the bike again, it was fine. I continued to ride the bike for a few months, then stored it again.

Right now, when I try to start it - starts no problem at all, revs fine etc.

As soon as I start to let the clutch out, the revs just drop right off - instantly. If I'm quick enough I can prevent the bike from stalling by pulling

the clutch back in.

I pulled the rocker cover off and tried to check out the KACR mechanism as I thought maybe there was an issue with this mechanism sticking on.

(It's listed in the factory manual as a possible cause for stalling under load)

The spring is still on the KACR, but apart from that I can't really tell how it is supposed to look. The diagram in the shop manual doesn't really make it clear.

Can anyone tell me, does this sound like a KACR issue?

Or is there a carb jet that could cause the same symptoms if it was blocked or stuffed in some way?

Thanks,

Dave

[XDragRacer]

Don't know about the KACR, but . . . the symtom definitely could be caused by a carb problem.

Besides possible gummed jets, a leaky diaphragm (split, perforated, or improperly seated and sealed) could cause the problem. Without an air-tight diaphragm seal, the slide will not rise properly, nor will the needle uncover the needle jet and main jet as power and fuel needs increase.

Regardless, hope you quickly and easily diagnose and correct your problem, restoring the power to which you're entitled.

[gilliganis]

Ok so if the slide assembly doesn't move at all, she'll stall the instant I let the clutch out?

I guess it makes more sense that the fault is from something gumming up and sticking, rather than the KACR being screwed, when all I did was let the bike sit.

[XDragRacer]

Ok so if the slide assembly doesn't move at all, she'll stall the instant I let the clutch out?

I guess it makes more sense that the fault is from something gumming up and sticking, rather than the KACR being screwed, when all I did was let the bike sit.

Could be something "gumming up and sticking," or--an air leak (compromised diaphragm) into the vacuum chamber, preventing the slide and needle from rising.

Does the engine rev up without hesitation when you open the twist the throttle? If so, maybe the diaphragm's not the problem.

This situation involves very long-distance trouble-shooting; good luck, nevertheless!

[gilliganis]

Yeah - like I said, it revs 100%

I don't know enough about carbies to understand which jet comes into play when the bike is stationery or idling compared to when it's under load.

I do know that I can wind the throttle right out, it doesn't matter if it's at 2000 or 7000 RPM, the result is the same - she just stalls instantly when the clutch comes out.

Don't worry too much about the distance either - we're used to it in Darwin for a few reasons:

a) We're in the southern hemisphere.

We're on an island in the southern hemisphere.

c)We're living in the smallest, most remote city, on an island, in the southern hemisphere.

I will rip the carby off again soon - just looking for as much advice as I get before then.

(Anyone else got any comments?)

Thanks for the suggestions,

Dave

[brewster]

With the bike in gear, can you pull in the clutch and roll the bike forward? Just checking to see if something in the drive train is jammed up.

A high voltage ignition problem may contribute to your stalling. A weak spark will cause problems under a load.

Good luck

Ride on

Brewster

[XDragRacer]

In case you look further into the carburetor, MotoMo shared this excellent link: http://members.aol.com/roundr1/CVK40.html .

[capnchaos]

did yo ever find out what was causing the problem with the klr 250 cutting out when you release the clutch? i am having the same problem

thanks

[capnchaos]

any idea what was causing the problem with the klr 250? i am having the same problem when i release the clutch it dies

thanks

[gilliganis]

I think it ended up being the sidestand switch.

I bypassed it. (Cut it off and soldered the wires together)

Have a look and let me know how you go.

Dave

[capnchaos]

Thanks for the help ....I will check it out and let you know

[capnchaos]

thanks i will check it out and let you know