KLR650 / DR650 “Carbonmakers”

Every time I turn the WR250R key to the on position and hear the fuel pump pressuring
the injection system I get the “willies”. Why? Because, to paraphrase Kevin Cameron
“Motorcycle fuel injection systems are very reliable, but if one fails, be ready for a long
walk”.

Fuel injection systems are far more complex and expensive than carburetors and usually
can’t be repaired in the field the way some carburetors can.

With approximately a million miles on motorcycles since 1955, I’ve suffered only
one fuel supply failure which occurred at Ojos Negros, Baja about a year ago. Rod
Morris and I came out of the dirt and went directly to the Pemex Station to air up the
tires for pavement. When I attempted to restart the engine of my DR650 it turned
over fine but wouldn’t fire. To make a long story short, a tiny fuel filter located inside
the fuel intake pipe of the carburetor had filled with particles preventing fuel flow.
Wow, I didn’t even know it was there.
The fix was easy:
  1. Remove the tiny factory fuel filter, throw it away, and refrain from ever installing a replacement copy.
  2. Install a larger, transparent in-line filter between the petcock and carburetor.

Fast forward. Mike Henshaw called me the other day to discuss a KLR650 problem.