I purchased a new 650 in July. It has had a part throttle hesitation since I bought it. I have had it back to the dealer 3 times and it's still not fixed. The first time They checked the choke cables, put new plugs in it. The second time I took it back they said the problem was at about 2200 rpms. So they replaced all ignition parts including the cdi box. I took it back again. This time they called kawasaki about the problem and rebuilt the carbs. I got a call saying it was fixed. So when I went to get it I tried it out and it still had the problem. They told me they didn't know how to fix it and said I should call Kawasaki. I am starting to get angry. Has anyone ever heard of a problem like this. Please Help!

 

I feel for you man, thats too bad. I think you just have not taken the quad to the right dealer. I guess I have been down on dealers a bit, and that's not fair. I have two excellent dealers near me. I think we only post problems resulting from a crappy dealer, not much gets said about the good ones.

This can't be that hard. If it is bad when it is new, there is definitely a defect. I am sure any real dealer would put forth the effort to investigate it and swap parts with another one to nail the problem down.


I think that kawi would make this right with you. You just need to get a dealer to go to bat for you, not say (I can't fix it). You can take it to another dealer. I know you don't want to drive it clear to my city just to find a good dealer, but let me know if it comes to that.

They surely can fix it. If they have to take it back and give you a different one. They are just trying to get rid of you, which is what you do when you sell used things, but not new ones with warranty.

I get all mad when I hear about a crummy dealer like that. I can't believe they gave it back to you and said they didn't know how fix it.

FYI, I luv my 650. It runs like a top. It thinks it is king of the forest, and sometimes I take it into rough places and have broken the plastic on it a bit. It just loves to go and play. I also skidded into my brother on his suzuki and made a little ding in my bumper. But wow is it a fun quad! Just wanted to give you some happy quad thoughts so you will be motivated to somehow get someone to fix it.

 

Mine does the same thing man! I can park and put it in neautral and give it gas and at about that same rpm or 1/8th inch throttle it will start to miss and cough,it is actually backfireing through the front carb. the front carb is to lean. if you look at the service manuel you will notice that the rear carb main jet is 2 sizes bigger than the front. this is to big of a jump, go up one size bigger main on the front carb so that the rear is only 1 size larger and Re- syncronize the carb's. this is IMPORTANT and see if the problem disappear's. I am going to put a Dyno-jet kit in mine but I'm sure this will fix your's. ALSO use 87 octane gas not 89 or 93. do these thing's and post back and let us know if it fixes it.

 

stakk, 1/8 throttle should be controlled by adjusting the pilot jets. Richen it up and it could straighten out your 1/8 throttle "miss and cough". Let us know if it works.

 

The dealer didn't try jetting? They must be a superwalmart or something that should not be allowed to service ATVs.

 

Actually I am going to redo my whole setup with the dyno-jet kit, that and my HMF should straighten everything out, I can't beleive that dealer didn't try to rejet that 650, that would be the first thing you would think? I mean replace all the electronic's and rebuild the carb's? I would let another dealer work on mine if it was me.It probably is the pilot, but a tuning shop said to that the rear cylinider does not need to be 2 sizes bigger in any of the jet's pilot needle or main's one size bigger is enough,they told me that even if you sync them that way, it will still try to run more off the rear carb, Jeff I know you said you sync'ed your carb's in another post, were they off? and have you jetted or checked the air screw's for adjustment? the dyno-jet say's to use their main's and needle's and go by their instructions and say to turn the air screw's out 3 turns, I'm just wondering what stock call's for?

 

Stock setting for pilots are 2 1/4 turns out. Mine are at 2 1/2 turns out. I have not touched the main jets. What I will do and what you guys should do if you want it to be right on for the main jets is to hook up an egt meter with one probe for each exhaust tube equal length from the each exjaust port. You'll know right away how to rejet to at least match them for your set up so that the front and rear cylinder are running at the same temp and air/fuel ratio.
Yes I synched my carbs. They were right at spec limit, so I made them perfectly even.

 

The service manager at my dealer told me he called Kawasaki and they told him to rebuild the carbs. So I called Kawasaki and they told me there is no record of any calls about my ATV. They told me that they would have a record of the call if there was one made. I'm not real sure how this works but I figured they would have to call them about it to get any money for doing the warranty work. I called my service manager back and asked him why he lied to me and he said he did call. I think he doesn't Know much and hopes I will just take it like it is. He needs to get a job as a walmart greeter. I told them I was going to get a lawyer if they didn't do something.

 

When I installed the Pro circuit pipe on my DS 650 the part throttle stumble became worse. Installed the Dyno jet kit and completely eliminated the problem. Good power from idle to rev limiter with zero hesitation. Engine seems to run cooler also.
Bearman

 

I hear that there is a recall on the 650. The carburator is flooding the engine. Call a different Dealer and ask them about the recall.