hey guys I need an advice if you like to comment. I have 2011 klx 250s fully original no addition kit or whatever.

I got fuel from a gas station from turkey/kocaeli Petrol Office company, I went like 5-6 km and took a break talked a few friends drank a cup of tea and head back to home. but unfortunately, I tried to start my bike again,it didn't. I tried everything that I could do in the middle of the road but in vain. my friend came to help and tried to increase air throttle or idle throttle valve to get the mixture more oxygen to increase the change of burning and increased it from 1.3 to 3k something but again it was not working. we tried so hard and then it all of a sudden started working but not stable I hold my gas position stable but the engine was going upto 6k and then again downto 2k like something was blocking the gas ignition and preventing the bike burning all the fuel inside the engine and the smoke was all black and smell was all unburned fuel.

anyway I managed to make it start and head back to home thinking that some dirt blocked the fuel system and using it on high RPM would throw it away. the next morning again it did not start.

I went to a local service (ordinary repair garage) as It is so hard to find authentic kawasaki service in where I live. the guy just checked everything completely renewed the cables and Throttle position sensor (TPS) for around 100$ saying it is really hard to find such part these days. also cleaned the fuel filter showing me that It was all black and completely blocked. and the following day I again hit the road and tried to do some cross ride and again after some the same thing happed on the top of a hill. it simply did not start. the bike started with 900 rpm and couldnt push itself above 1k. 2 or 3 try out of 10 run the bike but it was all by luck. it was starting with 1k and in two seconds it was going upto 3k rpm and then after some warm-up it was working normally but when I stopped it again, the same problem occurs. the problem was like the minimum requirements to run in idle mode were not met. it was stalling again. I paid 200$ in total and today I went back to the service again saying the problem was not the TPS the same problem still persists. The guy said I will try to change the whole gas filter but I don't think the problem is in the gas filter it must be something about the emission or throttle.

any comment is welcome

 

Is your KLX carbureted or fuel injection? Not sure what they sell in Turkey.

 

it is with fuel injection. sine 2011 or maybe 2010 they sell with the injection.

 

Your fuel filter was all black. My suggestion:
If you find out what made it black, you will probably figure out how to prevent this from happening again. Once you figure that out and correct it. (Maybe clean the tank out, throw the gas away, clean the filter, get new gas.)
Then get the injectors & throttle body totally clean, it will be fixed.

 

Hey durielk,

thank for your reply. When this incidence happened, I cleaned the tank emptying the fuel out of it. but the black dirt on the filter is possibly created by long use without any maintenance by its old owner. I just get the bike like 6 months ago and still cleaning and trying to fix it up.

 

OK, if I was still having problems, the next items to look at:
1. Check the plug & replace it (cheap & easy)
2. If that doesn't help, you may need a new sensor that is located in the exhaust. I would take that out and clean it (if possible) and/or replace it.

 

hey dude

now another problem the old problem still persists tho. anyway exhaust exit from motor block was fire-red and burning really hot although I went something like 7-10 km with low speed. i am really messed up

 

I would check the basics-make sure that fuel pressure is at spec when the problem exists. That will tell you if the pump or filter is having a problem. If the bike is blowing black smoke from the exhaust when it looses power then it may be having an issue with the map/baro sensor. The computer looks at throttle position and engine load(map signal) to determine how long to open the injector. If either of those inputs gets scrambled it can cause the symptom you describe. Another possibility is if the coolant temp sensor unplugs or looses continuity the computer thinks that the engine is stone cold and will add fuel like a choke on a carb. Make sure that the harness/plug for those sensors are in good shape.

 

Hey GBAUTO,

thanks for your concern and time.

honestly the thing you told is the exact thing that I suspect. because each time I start the bike it stars with low idle no matter how hot the engine is. then I increase the idle mod manually each time.

and another garage has just told me that the heating may be caused by the replaced TPS, the old repairman must have used different TP sensor therefore it creates rich fuel which is not suitable for your bike (and probably from a kawasaki racing bikes). If you continue to use it like that, you are gonna damage / or already damaged your exhaust valves.

the bad thing is that the exhaust becomes so hot that I am so hesitant just because it may damage plastic oil pipe which goes in front of the motor block.

I'll keep this tread informed when I find a suitable and exact solution to the problem.

 

hey again,

I've just gone to the first garage and got the replaced parts and checked the TPS connector installed. and it is definitely not the same OEM number as my previous one.

that must be the problem. the new one on my bike is something like 500BC2 0-229something and the original one (malfunctioning) is 500BC2 0900A ( for klx 250s 2011) this must be the problem which malfunctions the mixture ratio and sending rich fuel into the motor block which at the end produces much hotter outburst and then my exhaust pipe (the point where it exists from the block) make it burn like a lava.

I found a video on youtube about how to clean Throttle Position Sensor


gonna clean it and tell you about the results.

regards!