Hi guys, just been having some probs with my 99 KLX250H,
I can start the bike fine when it's cold with the choke & it idles to warmup temperature with no problem. When I crank the throttle to around the 3000rpm mark it misses like it would when it's cold, after about 5 or 6 times doing this or attempting to ridethe bike aroundthe engine dies out completely. This happened after I started practicing a few wheelies & after I had changed over the two fuel lines running from the fuel tank to the fuel selector tap. Another interesting point is that the bike behaves normally when I change the fuel over to reserve.
I wonder is there simply a partition in the fuel tank separating the main fuel & the reserve? I wonder too if I just run the bike on reserve whether it will run out of fuel because the reserve tank is going to be smaller or if the reserve would still get fuel from the main part of the tank?
I'm sure this is a fuel problem because of the fact that it runs fine on the reserve setting. Any ideas? I'm pretty stuck here. [X(]

 

Make sure your tank is farly full before doing this test (as least half way).
Turn off the petcock and pull the line that feeds your carby. Get a bucket or mason jar and run fuel into itin both 'reserve' and 'on' positions. Fuel should come out at about the same rate for both positions. If it doesn't, the slower postion is partially blocked by something. Use bailing wire or something of the sort to clear the blockage.

Also look at your hoses to make sure they aren't kinked or routed in some peculiar manner.

 

Thanks Trem, I think you're right, I tried that test & fuel only came out when the tap is in the reserve position, I must have somehow dislodged some sediment in my tank or maybe got some dirt in the hose fitting somehow. I'll pull the main hose off tomorrow & try using some wire to unblock the tap. I'll let you know how it goes, here's hoping it's just something simple like that. [sm=smiley1.gif]

 

I would remove the tank and separate and disassemble the petcock and clean everything out thoroughly to prevent myself from becoming a bike pushing pedestrian down the road if you find or suspect any foreign objects in the fuel system.
There is a filter screen inside the fuel petcock that you will want to clean. You may also want to check the little white plastic fuel filter located in the plastic inlet elbow to your carburetor, it may have some debris that could build-up and cause more issues down the road.

 

Well I can't disagree with a little preventive maintenance,however bothmain and reserve run through the petcock screen as well as the carb bowl filter, soif he just wants to get it running normally he may not want to go straight for the ultra meticulous route.Once heclears theblocked'on'feed and lets the fuel run into a container, avisual of the inside, bottom part of the tank might be a a good idea.

To each his own though.

How's the P-bomb Q4 combo working for you?

 

Dean,
My recommendation was meant only as an addition to what you had posted; mainly if he had dislodged some crud to prevent a reoccurrence or worse, not instead of what you said. It is pretty obvious that the blockage lies somewhere between the main fuel side of the tank and the fuel selector petcock.
If you have contamination in the fuel tank that has already partially blocked a line there is a pretty fair chance that the contamination is system-wide, even if not it’s only a 15-30 minute job to r-and-r the tank and check the screens not really all that meticulous and not exactly preventative maintenance either as the cow seams to have already left the barn in this chaps case. On a several year old steel tank bike rust scale growing in the tank is common and suspect.



The FMF exhaust on my little KLX works well and doesn’t sound like a worn out cement mixer any more, no complaints, I've put an FMF system on all my dirt bikes over the years and have always been very pleased with them and no exception here.
I just ordered a Q2 for a DR650SE I recently purchased as well, anybody that thinks that the KLX has a heavy silencer hasn't seen the monster on the Suzuki.

 

Thanks for your help guys, I was actually kinda curious to know about extra fuel filters or screens like you mentionedthat you find on the KLX so thanks for letting me know about that.Is there a fuel filter in the tank itself?
Anyway I found the problem for now.I hadn't actually noticed or realised but when I changed over my fuel hoses from the tank (they were looking old & perishing) I had too much length on the main one & it ended up with a kink in it. So I just shortened it a little, put it back on & it ran perfectly afterwards.
Next time I do some maintenance I'll take the petcock off & disassemble it & give it a good clean.
http://www.tac9.net/cl/KLX-01.avi

 

here is the stock fuel filter







i added this....

 

Great contributions! Myhatgoes offto all for a very productive thread.

I should probably start using one of those inline filters; that's a good idea.

Good inspection recommendations from ZX1100 as well.

Glad to hear you fixedthe problemPointman.

 

Yeah, fantastic EMS, pics make all the difference! thanks dude!