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KLR 650 Engine stalls while driving KLR 650 Engine stalls while driving
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  #1  
Old 17 Aug 2021
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KLR 650 Engine stalls while driving
Hi!

I had a problem with my motorcycle while traveling in Brazil and want to consult with you about the possible causes.

The bike is a 2012 Kawasaki KLR 650. The problem is that the engine stops when driving for no reason. It can happen during normal driving, as well as during acceleration or just driving out of the garage. It happens randomly for no apparent reason.

After that, the moto either does not start at all, or it can be started after a while.

I tried to fix the problem at motoservices in several Brazilian cities. Usually the mechanic would open and clean the carburetor and check the spark plug. After that, the problem disappeared, but came back in 1-2 days.

What do you think the problem could be related to? I am going back to Brazil to continue my trip and want to know what motoparts to bring with me.
I would be very grateful for your advices.

Thank you!
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  #2  
Old 17 Aug 2021
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klr
It could be a wire rubbing on metal.make sure there is no wire grounding when your key switch is on OR [on off kill switch ] to the ignition coil,
that thingy that has the spark plug lead.
The Coil has to be open No continuity to get spark [ Grounded to stop spark]
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  #3  
Old 17 Aug 2021
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I've had similar problems twice in ~100,000 miles on a 2007 KLR. Once involved the kickstand kill switch, in response to which I jumpered around it so that instead I occasionally take off riding with the kickstand down (not recommended).

The other time was more puzzling, and turned out to be a detached baffle inside the muffler--sometimes this had no effect and the bike worked fine, at other times it merely choked off power above a certain speed, while on rare occasions it stopped the engine entirely without warning. Following lots of carb maintenance, wiring and fuel delivery checks, and other such stuff, I finally heard an audible "clunk" from the muffler while under way at the precise moment that I lost power.

Intermittent failures are ridiculously frustrating, especially in 2008+ models which rely increasingly on electronics. Sometimes, as with my defective muffler, solutions require sidestepping normal tunnel vision--in my case, I was absolutely certain I was dealing with a fuel delivery or electrical problem based on the symptoms.

Hope that's helpful, and good luck!

Mark
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  #4  
Old 18 Aug 2021
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Quote:
Originally Posted by tohellnback View Post
It could be a wire rubbing on metal.make sure there is no wire grounding when your key switch is on OR [on off kill switch ] to the ignition coil,
that thingy that has the spark plug lead.
The Coil has to be open No continuity to get spark [ Grounded to stop spark]
Thanks for the tip! So you recommend to check wires insulation between ignition coil and kill switch?
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  #5  
Old 18 Aug 2021
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Quote:
Originally Posted by markharf View Post
I've had similar problems twice in ~100,000 miles on a 2007 KLR. Once involved the kickstand kill switch, in response to which I jumpered around it so that instead I occasionally take off riding with the kickstand down (not recommended).

The other time was more puzzling, and turned out to be a detached baffle inside the muffler--sometimes this had no effect and the bike worked fine, at other times it merely choked off power above a certain speed, while on rare occasions it stopped the engine entirely without warning. Following lots of carb maintenance, wiring and fuel delivery checks, and other such stuff, I finally heard an audible "clunk" from the muffler while under way at the precise moment that I lost power.

Intermittent failures are ridiculously frustrating, especially in 2008+ models which rely increasingly on electronics. Sometimes, as with my defective muffler, solutions require sidestepping normal tunnel vision--in my case, I was absolutely certain I was dealing with a fuel delivery or electrical problem based on the symptoms.

Hope that's helpful, and good luck!

Mark
Mark, thx! How did you determine the problem with the muffler and how did you solve it? Replacement?
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  #6  
Old 18 Aug 2021
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klr
Quote:
Originally Posted by alexanderyork View Post
Thanks for the tip! So you recommend to check wires insulation between ignition coil and kill switch?
yes and ignition key switch could be chaffing on the frame or your coil is on its way to total failure
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  #7  
Old 19 Aug 2021
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Quote:
Originally Posted by alexanderyork View Post
Mark, thx! How did you determine the problem with the muffler and how did you solve it? Replacement?
As I said above, I heard a loud "clunk." Replacing the muffler was the only answer.
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