Diesel KLR 650 running video

[Tx-Ranger]

Here is a video of the "sparky" Diesel KLR 650 running.
It took awhile to get it running, the old biodiesel was gummed up and the petcock was dirty.
Once petcock was cleaned and the lines cleaned it started after about 30 pulls, battery was dead!!!
I cleaned and added a fresh batch of biodiesel.

http://tinyurl.com/376p9wd

[Sphere]

Nice What engine is in it, a Yanclone?

[Tx-Ranger]

DEK F420

It will be changed to Yanmar or Winsun atbsome point.

[Curtis in Texas]

Guy, are you still on the Board?
There are several of us locall N Texas Folks who would like to get to know you.
I saw Balboa71's bike last night. Very cool.
I live just down the road from you off of 407 on the north side of Rhome so we're neighbors almost.

Give me a hollar and let's see if we can meet up.

I'll be building a KLR copy of yours later this year.


Curtis

[coachgeo]

Top end appears to have been accidently limited on this bike from what I hear. Curtis is fooling with it and there appears to be conflict with frame member not allowing the back CVT pully to get fully expanded thus not letting it get to top of its ratio. Their tweaking it to see what can be done.

Will update ya if hear anything more.

[SamM]

Whatever happened with this motorcycle?

[coachgeo]

Whatever happened with this motorcycle?

more info here

viewtopic.php?f=23&t=2289&p=14977

[coachgeo]

more updates next week.

Here is the old for sell thread on this bike. https://www.dieselbikeforum.com/view ... f=5&t=2177

[coachgeo]

Here is a video of the "sparky" Diesel KLR 650 running.
It took awhile to get it running, the old biodiesel was gummed up and the petcock was dirty.
Once petcock was cleaned and the lines cleaned it started after about 30 pulls, battery was dead!!!
I cleaned and added a fresh batch of biodiesel.

http://tinyurl.com/376p9wd

Sparky gladly put the video back up for us. Here it is

https://www.youtube.com/watch?v=HbDcLHv ... e=youtu.be

[coachgeo]

Well, rode the KLR a bit. The hand throttle allows the fuel to go all the way down to shut off. Made it a high learning curve to not accidentally shut her down. Hard lesson to learn fast when the battery was low from sitting and bike could not be restarted. (rope pull presently broken recoil spring). Knew I had to do something about that.

Many iterations of trying to re-incorporate what Sparky had once done. I finally gave up on trying to make a spring loaded lock that would pop into place when hand throttle got turned just enough to keep her at idle. This had rattled off long ago. When got done ended up that some Changes AFTER Sparky made the original Spring Pin it ended up holding things at FULL THROTTLE. .... Good 10 hours wasted.

This morning I created a new location for just holding it at idle. Now I have a screw in post with a spring. Hoping the spring keeps it from rattling loose while driving. So at start up you move the throttle and screw in this throttle stop. Hold the Compression Release open (nice thumb choke cable Curtis installed) and hit start. She fires right up and idles nicely. When at destination, unscrew the stop so hand throttle can go all the way home .... whala, bike shuts off.

Yeah.... I can just shut down with the compression release but... have read that is not good for the engine. Am I correct that throttle all the way home on Yanmar Clones is something like a fuel shut off which is why she shuts down?

Photo. Black bolt with black fuel line (spring mentioned above is under that) is one installed to hold idle. Empty hole below that is where Sparky had installed a pop in pin to hold at wide open.

. PS- She barely gets to 50mph. Already picked my routes to work that are neighborhood-ish / back-way that makes those speeds doable. 15min drive or so.

Today Curtis and I load everything in a Uhual for my trip starting around 5 am tomorrow. Starting early to avoid Dallas Traffic. It will be a two day drive.

[Diesel Dave]

You should have 2 threaded stops on the regulator (there are several different types so the location can change from top to side), one will be the max rev and the other the idle setting.

The max fuel is usually from the bottom or LH side (when viewed from the rear of the motor) so easily identified, on the proper Yammer's this is a sophisticated bit of kit with a thermal wax element for cold starting enrichment - on the clones you just get a bolt.

I'll see if I can get a picture or 2.

[coachgeo]

Now to be fair... part of the 10 hours was working on the Rope Pull cover followed by starting issues. Cover had to be put back on for safety so pant legs do not get caught in spinning parts. That was followed by.... battery charging..... but apparently not holding charge cause it wont spin the engine even though good voltage.. Nice AGM in it then with high CCA. Went got new cheap 50$ battery. Followed by more charging and bull shitting with Curtis about life lessons. He left then for the evening Graduation activities and I dicked around with the no spin issue. Geeeeeezzzzz would you believe the rope pull cover we reinstalled had an interference problem and was stopping the engine from spinning. grrr... that was 3 hours of the 10. So now I got a great AGM and a second unneeded Motorcycle battery.

Today is now Tues. Noon. Curtis again at Grandchild Graduations and family gatherings. (second grandkid) Should be home in hour. We'll tackle some stuff on Tiger. Then load it all.

[coachgeo]

You should have 2 threaded stops on the regulator (there are several different types so the location can change from top to side), one will be the max rev and the other the idle setting.

The max fuel is usually from the bottom or LH side (when viewed from the rear of the motor) so easily identified, on the proper Yammer's this is a sophisticated bit of kit with a thermal wax element for cold starting enrichment - on the clones you just get a bolt.

I'll see if I can get a picture or 2.

Question still remains..... is shut off typically done by getting her to drop below Idle to shut her down. Im going to feel stupid if your suppose to use the compression release. My Kubota contacts have always said compression release shut down was bad for engine. Maybe that is just a Kubota or multi cylinder thing?

I did see that where where adjustments on the lever at the back of the engine. Curtis said he had already set them as best as possible.

Look forward to your info. Will be interesting to compare them to help see what Sparky did to install the twin cable (push pull) hand throttle vs OEM. Do recall someone posted in the past how to redo some things with the linkage to make it more of a throttle and less of a rev. maintainer (is that right description?) of these industrial use engines.

[Diesel Dave]

The short answer is 'yes', they don't have a separate shut off lever like old Lombardini's, Robin's etc.

You can fit the electric stop injector pump:


On my old setup - I had the 'throttle' cable outer terminating in a top hat that sat in a strong spring, that way idle speed could be set and then a lever compressed the strong spring to shut off.

It's a very dodgy setup on a motorcycle to rely on the cable tension to set the idle speed, guaranteed it will change as you turn the bars.

Here's the current setup with the two threaded stops, the on on the left is max revs, and the one on the right with the pink dot is idle (and it's VERY sensitive).

[coachgeo]

Is that a single cable throttle control? One on this bike is dual cable. Curtis said that was a safety feature so if throttle cable breaks one can still throttle down and not be stuck at wide open.

Mine also changes speed a smidgen when turning

Anyway.... got some pics and even a video of what I have. Will see about uploading. I'm on realllllll slow internet.

Pic is from flywheel side

[coachgeo]

Notice that added pictures for David in previous post. Will delete this post later.

UPDATE:
hmmm..... ok..... seems I can't delete this. Moderator feel free to delete this

[coachgeo]

Could have swore I saw a question on what engine was in it but now dont see the question. Anyway it was sold by DEK / GEK . Not sure manufacture http://www.dek-engine.com/engine-index.htm

Model F420

Diesel Engine Technical Features (new)
Model......................F210.......F220.......F300.......F310.......F400.......F420......F440[/b]

Type Single-cylinder vertical 4-cycle air-cooled direct direct spraying diesel
Displacement cc.........211.........219.........296........306........406........418.........435
Bore x stroke mm......70x55......70x57.......76x82......78x64....86x70......86x72.......86x75
Speed rpm..............30x/36x..30x/36x....30x36x......30x30.....30x/36.....30x36x.....30x3600
Maxi output H.P..... .3.8/4.2..4.2/4.6....6.1/6.6......6.5/7.2..8.8/10......9.6/10.5.....9.8/11
Continuous H.P. .......3.4/3.8..3.8/4.2....5.5/6.........5.8/6.5...7.7/9......8.8/9.6....9/9.8
consumption g/hp.h..209/218..209/218..201/210.... 206/215...201/210...201/210...201/210
Compression ratio 21:1 22:01 21:01 21:01 20:01 20:01 20:01
Power take off Crankshaft or camshaft (Camshaft PTO rpm is 1/2 of Crankshaft)
Governor syster Centrifugal weight system
Cooling system Forced air
Starting system Recoil or Recoil/Electric
Fuel tank capacity 2.5 2.5 3.5 3.5 5.5 3.5 3.5
Lub.Oil Capacity(L) 0.75 0.75 1.1 1.1 1.65 1.65 1.65
Length(mm) 430 430 480 480 525 525 525
Width (mm) 370 370 450 450 470 470 470
Height(mm) 465 465 525 525 585 565 565
Weight(kg) 35 35 41 41 56 56 56
Noise Level 82dB(A)at4mts 85dB(A)at4mts 88dB(A)at4mts

[pietenpol2002]

Coach,

I believe I have a pump with a solenoid shut off if that would be helpful. Probably have some spare pull starts as well if needed.

[coachgeo]

Coach,

I believe I have a pump with a solenoid shut off if that would be helpful. Probably have some spare pull starts as well if needed.

Yeah look thru what you have. May be interested. Want to get using the KLR as soon as possible. Costing over a Grand to come get everything here in TX and am about to pay a HUGE chunk of money to pay off my house thus using the bike ASAP will have made it less painful overall when all is said and done.

[pietenpol2002]

It'll be next week until I'm back in town to rummage.

[coachgeo]

Well rode the KLR right down the ramp of the Uhaul truck on Saturday 3rd. As mentioned in the US Tiger thread, unloaded rest of the bikes with my tractor and friends help. (see video in that thread)

Tonight (5th) took KLR for a spin to check out lights. Looks good. Plan to commute with it for work tomorrow and since I do not get off work till 9:30pm-ish wanted to make sure the lights were all up to snuff.

[UAofE]

I use the choke lever on my bike's handlebar to pull on the main governor arm.

[coachgeo]

she ran really bad with low power and high black smoke other night on return home. Sooo. she got parked for some work.

First thing...... fuel system. Wanted to drain it to see if any water was in there...... (NO there was not) Used a water remover filter/Funnel. Granted they say it will NOT remove water if there is additive in there....... and there is.. I previously put in Diesel Service Clean.

Second.... found the fuel tap at bottm of tank was falling apart. If it was not gravity fed... It would be leaking air. Ordered new not OEM one. Replaced old one with it. Was pretty gunked up anyway.

Third... pietenpol2002 in here offered up an IP with a fuel stop solenoid earlier (Again MUCH THANKS) so now would be time to swap it in to eliminate a fuel pump issue. Will discuss this some in a Fueling thread. More here viewtopic.php?f=33&t=3360

Fourth... Replace fuel Filter. discussed in thread here > viewtopic.php?f=33&t=3358&p=24599&sid=3 ... d60#p24599

Fifth.... Clean Injector..... Damn thing is STUCK. Will add link to thread on removal discussion.

Sixth...... Air filter. Not got that far yet. Will add link though.

[coachgeo]

No one seems to be reading any of this but for shiats and grins here goes anyway.

Got the pump and injector installed. Brass shim that came with the pump was marginally thicker than one on mine so I did not install one of the paper shims that was on mine. Could not see into the pump's peep hole due to Bike frame and every other damn thing in the way. Tank is removed..... but even with that off was left with trying to use my phone to video in the peep hole for a good 45min... gave up and just had to go with an educated guess that she is aligned right and installed correctly.

Since I'de soaked the engine in ATF/Cheap oil.. drained that and put sacrificial lube in her. Will be drained after she runs a bit and fresh oil put in.

Ran out of time.....

next day at it will install bikes fuel tank and few other things (new air filter and holder and some new rubber mount parts) and refill with fuel thru a water removing funnel.... then try to get her running again to see if this solves the problem. Think it will. Not knowing what is "normal" for sound of this engine... still think she was nailing pretty hard.

Adventure continues.

[Tetronator]

No one seems to be reading any of this but for shiats and grins here goes anyway.

Well, at least I'm reading this. Just don't have anything to add.

[mark_in_manchester]

Aye, I'm reading too. Why risk ones' limited reserved of self-respect by f***ing up a job in the shed when you can watch someone else f***...ahem...get inspired watching someone else making a great job of rebuilding their bike, on the internet?

Again, different bike, different engine, I can't say anything meaningful. Not that that often stops me.

[pietenpol2002]

Oh, we're reading Coach. But to comment only exposes my short supply of experience, knowledge and wisdom. The world is a better place if I just step away from the keyboard. But, do keep us posted on your adventures.

[coachgeo]

Hopefully someone learns something from my Fubars etc.. Only reason I post it.

[coachgeo]

Installed tank and put fuel in. STUPID ME lol. Discovered should have done this later.

Went to prime the system.... ooops.. the Fuel Shut off solenoid needs power to let fuel by. grrrr... so it is an always closed solenoid.

Dug thru wiring diagrams and conversed with folk on a KLR board and deciphered where to get a switched hot. Got lazy and used a new version of the clamp over wire thingamabobber.
(Dorman T-Tap https://www.youtube.com/watch?v=ikZZBmvFEho ) Will seal it well with electrical silicone and tie it off to adjacent items so it does not wiggle and cause breaks/shorts. These clamp on things are known to create weak points so I want to keep it more affixed. Wanted to get an adapter (one female spade to two male spades) to jump off a nearby in-use male spade.... but of course no one had any. Put a wire loom around the Injector overflow line and ran the wire thru loom as well, back to the to the Solenoid which sits on the Injection Pump (Jack Pump) just prior to the Injector line. Planned this idea to keep the wire from flopping around near exhaust and hot engine.

Was a bit of a PITA with the tank on but think I managed. About this point ... working in front yard and Night was falling as well as mosquito varmints attacking decided to save test and hopefully bleed air for another day.

Covered bike again... supposed to rain off and on all week. SO TIRED OF RAIN. A tree fell in back yard other day. Ground too wet to support the old rotten (partially cut down) tree. Just missed the Spare Tiger.

[coachgeo]

grrrr...... looks like the fuel solenoid in the IP is bad. NO FUEL. Solenoid is powered.