Hey man I got an 02 P650 and have just started having the lock up problem when trying to start it. I noticed you said something about it in an earlier post. What is this all about? I have had several problems with my quad that had to do with the carbs but my dealer is not as familiar with the quad as I am. My choke cable isn't working correctly and it is almost impossiable to start without giving it gas. Even then it doesn't want to start like it should. I agree with the statement that the quad is hard to beat when running right but with all the problems I have had I'm starting to look at some of them old outdated honda quads again. I'd rather be riding than waiting on my ride to be fixed. Any info on the gas leaking by the carb or whatever it is that causes the lock up problem is appreciated. Thanks.

 

the gas leaking through the carb thing is easy to fix. the dealer told me just to turn the fuel petcock off when you shut the engine off. i thought it sounds like there is something more wrong with it if it is leaking through, but the dealer was told to do this right from kawasaki. too me they sould make some sort of elec. shut off in the fuel line so when you turn the key off the fuel shuts also. anybody try something like this yet.

 

I too think the Kawie VTwin engine is great.
Part of my problems was due to the dealers poor set-up of my P650.
I had the problems with my 1st P650, a 02 model, same choke problems which took 3 months to fix & then a starting problem that took the dealership 9 months to figure out what was wrong. All it turned out to be was both the Neutral & Brake Relays were bad, once both were replaced with new relays at the same time, I never had anymore starting troubles, after about 10 round trips to this dealership (300 miles each time, round trip) I was happy that everything was finally fixed. Then I sold it & bought a New Again but this time a '03 P650 camo model. I just felt that between the poor dealer set-up & being this '02 was a 1st model year P650 that it was just a fluke & I was right. The '03 650 was Set-up correctly this time from the same Dealership, I made sure of it. I have had a minor problem with the 4wd actuator acting up on the '03 P650 once but it just turned out to be a dirty fuse connection, easy fix. NO other problems at all.
The ONLY reason I sold this great '03 P650 is it is only going to cost me $300 to try out a Cat 650 with the same excellent Kawasaki VTwin 650 motor/trans. I can really use the extra ground clearance that the Arctic Cat offers.

 

Whats the choke problem everyone has been talking about? Mine seems to be sticking and continuesly choking the engine not allowing it to idle correctly. Is this it? Thanks.

 

My Dealer told me it was weak choke springs that was causing the choke problems.

 

What I meant was what did the quad do to alert you that something was wrong? Did the choke stop working or was it hard to start and then not run right? I'm having some terriable problem with mine now and it sounds like a hammer beating in the front cylinder. I'm thinking that maybe a bent rod from the hydro locking. Its going to the dealer tommorrow but I'm not sure they know any more about the thing than me. Anyway thanks for the info so far. The more I know of things that have happened with others the more likely I am to get mine back running right. Again thanks.

 

Guys it's the choke springs!There was some talk about the cable being too short but the new cable has the same number.I had the same problem with my 02.I got the springs out of a klr 650 dual purpose bike.You have to order two.This WILL fix the problem.The orig springs do not return the plunger all the way.I ALWAYS had to use the throttle to start mine but now I don't Since the springs do not return the plunger it is allowing fuel to get in and thats why teh need to use the throttle.Once you get the old ones out you will see what I mean.My front one was not returning the plunger at all.I am not sure about this fuel shut off deal.The tank is below the carbs and it has an electric pump....how is fuel getting there when the key is not on???
02 650 camo

 

The fuel petcock problem was addressed on this forum before but it was some time ago. I don't remember exactly the cause but the owners manual does say to turn off the petcock while your P650 is not being used. Somehow, by leaving the petcock on the "ON" position, gas was still being sucked up the fuel line & thru the carbs & into the engine. I've noticed some times there is a lot of pressure in the tank after I let my 650 sit for a few days & when I remove the gas cap you can hear the air escape.
Is it possible that this tank pressure is pushing the gas up to the open petcock "ON" & dumping it into your engine?

My choke problem was wierd. My P650 would run like a rape ape at the dealer & at 4300 ft elevation but run like a dog at 8000 ft elevation, no power & lucky if I could get up to 40mph going down hill. Had the jets change for higher elevations & same results. It took awhile but it turned out to be exactly what Kodiac1 said.

 

The tank is vented to allow air in, but will not let excess pressure out. When the excess pressure builds up, fuel is forced past the carb needles and if the enrichener valve (choke) is stuck on even slightly, gas will pour into the cylinder. Heavier choke return springs help this problem, several people have also removed the check valve from the gas tank vent.

 

where do i get a set of the springs for mine. also where is the one way valve for the vent located