My 650 was running like a champ for quite a while after I had my jet-kit installed... It is set to the factory defaults but would start and run much smoother than the stock jets. It's been a few months now and I'm having trouble with it stalling out while idling. I have adjusted the idle screw but it doesn't seem to help it still will studder and eventually die. It also doesn't start very well anymore.

I should point out that I know almost nothing about these machines (except that they are a riot to play with) but it sounds like it is running too rich. Normally if I were to leave the choke a little bit it runs rough - That is what it seems like is happening. I checked the plugs yesterday and they weren't too bad. This has only been going on for about 2 weeks, only been ridden 2 times since.

I hear people talking about their choke cable springs, could this possibly be the problem?

Any I.D.-Ers?

 

Dig650, You should also mention what size jets you installed and where the airscrew is and needle. Also your altitude and temperature. If it runs fine everywhere besides idle you probably just need to adjust your idle, not your jets. Tell me more and I could offer some advice. I just went thru the same thing. A fellow by the name of STAKK really seems to know his 650 jetting and helped me with my problem. --T650

 

It seems that there is another main topic "650 stalling" he seems to be having the same problem.

Not sure what my exact level is but its anywhere from 500-1000ft. We had a fairly warm winter and it ran perfect all the way through haven't changed anything on the machine since the jetting. I had my dealer install the jet-kit and they them to whatever Dyno recommends without a performance exhaust. It stalls at idle but it also runs rough all the way up.

I'll keep an eye on the other topic as well...

 

In case you haven't seen where it say this, the dynojet kit says turn both air screws in until they stop, then turn them out 3 turns and see how that makes it idle and start. The possibility of choke cable probs could make you stall.

The dynojet instructions make the quad run rich. Everyone I know with a 650 at your elevation (w/stock exhaust) has been using the needles on one notch leaner (4th notch) than Dynojet says. This only made mine hesitate when stabbing the throttle, it does not sound quite like what yours is doing.

Also, take a look inside the cover in front of the handlebars and make sure that you can see the end of the airbox snorkle (above and to the side of the radiator cap) , since some people have stuffed the airbox into place with the rubber shield covering the opening. This makes the 650 run bad too.

Sometimes you gotta do the jetting yourself, since the dealer won't take much of a ride on it to verify that it is right.

If you haven't already, put some holes in the airbox lid too.

 

I would think that it would be something other than the jetting where he says that it ran fine for quite some time.I would definately check the choke cables out as well as the air filter(make sure it isn't getting plugged up)

 

Sound's like the choke sticking, if it ran good and just started doing it out of the blue, I would bet it's the choke cable's, the dealer's are well aware of this problem and should replace it free if it is sticking, stalling at idle speed just about guarentee's the sticking cable's. after you have this checked and it is still doing it, I would back the air screw's to 2 1/2 turns out, stock is 2 1/4 out, if you don't have an aftermarket exhaust, you may not need it 3 turns out, Put the needle clips in the 4th notch instead of the 5th if that's where they are set, It will never clean up at the 5th slot, that's just to rich from what I've seen and I have jetted several for people. another thing my 650 will not run right on 93 or even 89 gas. try 87 after you do these thing's and see if it get's better.

 

Stakk, could you explain why it would run better on lower octane gas?Does it make it run a little hotter?

 

To be honest I don't know it's run's better on 87, It is a hotter burning fuel but it don't overheat, it makes more power with reg. when I put 93 in it cough's and fart's and will miss. Go figure, back to 87 runs fine. it may just be my bike and where I live. One thing I did was go to CR8E plug's.it lower's your head temp about 5 degree's. Also if you put the HMF on with the rear headpipe that comes with the muff and leave the stock front header pipe on the bigger one that is on the rear will throw the carb's out of sync, so get them re-syncronized. I would do it even it the exhaust is stock, I think they recommend this at the first service with the valve adjustment. If the carbs are sync'ed, jetted right,and the quad can breath, this thing's are wicked.

 

After the dealer installed the Jet-Kit it started and ran perfectly for 4 months or so. The only thing that has changed is the choke has been in and out during starting and early riding. I got some uni-vents just haven't installed them yet maybe that will help. It doesn't seem like the choke is "sticking", assuming its the problem, it just seems like when its pushed to the normal position it may still be choking a little.

Is it possible to adjust the jet settings without taking the airbox off? I see there is a few screws on the bottom of them is that where its done?


Stakk, I've been running it on 93 since day one and have had no problems thus far.

 

The choke won't stick at the handlebar it will stay partially on in the carb's mainly the rear carb. some of the cable's are too short from the factory and will not go back all the way in at the plunger's. Tell your dealer you want a new cable put on and if they try to make you pay for it call Kaw. you can change the main's without removing anything if you have a long screwdriver and calm nerve's. the airbox must come of to get to the needle's, they need to be in the 4th notch regardless. do the choke cable first then the needle's. that may be all you need. to be honest with everyone the 650's don't need 93 gas, if you want to use it and it run's ok then it's fine, but from my experence, you're only wasting about 20-30 cent's per gallon,they wont run any better than if you had reg. in them. mine does not like the colder high octane gas for some reason, maybe it's just the way the gas is blended here in the southeast.