KLX needle question - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 14 Old 03-11-2014, 01:20 PM Thread Starter
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KLX needle question

So.........I pull carb on the 2005 KLR I just bought to shim the needle. Low and behold it has a KLX needle already in it and the slide drilled to almost 1/8" (wire #31). Great!! I put it all back together and did the frugal exhaust mod and pulled the snorkel. Started great, sounded great but i didn't actually ride because the bike is in many pieces right now. However it ran great before I started disassembly to clean, restore plastics and do mods.

Anyway............I am looking at a KLX needle kit on line just to learn a bit about it. I see that it sells with a needle, clip and brass washer.

UUHHH.........I don't remember seeing a brass washer. I thought i looked down in the slide before I put it all back together but now i am questioning myself. So.......maybe the brass washer is now not on the needle.

Am I destined to go back in and look for it or would it have been obvious like rattling around, blocking the vac port, not start/run right........something?? Is that brass washer a MUST with the KLX needle or did the PO possibly not use one??

Yikes.........paranoid..........help!!!
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post #2 of 14 Old 03-11-2014, 01:34 PM
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EDIT: The following post may be nonsense; the brass collar/spacer may be of structural significance; see posts below.

The washer is used only to "fine-tune" the needle height between grooves.

Apparently, the PO was satisfied with the needle clip dead-on a groove, and didn't need no stinkin' washer.

If you decide you DO, you can pick up a # 4 washer at the hardware store; doesn't HAVE to be brass!

Last edited by Damocles; 03-11-2014 at 10:49 PM.
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post #3 of 14 Old 03-11-2014, 01:37 PM Thread Starter
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Whew.......thanks!!! That eases my paranoia!!

Lets say the washer IS in there......and NOT on the needle. Is it gonna cause something to blow up or ruin the carburetor??
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post #4 of 14 Old 03-11-2014, 02:19 PM
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The washer goes under the clip; it cannot escape and run around the carb. I have several washers and they are either under clips inside carbs or in the AOL tin of jets, needles, and washers. Different brass #4 washers can be slightly different thicknesses so I measure them and fold them into paper with the thickness written on it. Not required for a KLR, but for a 4-carb bike I'd like them to be as close as possible.

If your bike runs fine you may never need to locate the washer. But it'll be either on the needle (under the clip) or not in the carb at all.
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post #5 of 14 Old 03-11-2014, 03:30 PM Thread Starter
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Quote:
Originally Posted by Grinnin View Post
The washer goes under the clip; it cannot escape and run around the carb. I have several washers and they are either under clips inside carbs or in the AOL tin of jets, needles, and washers. Different brass #4 washers can be slightly different thicknesses so I measure them and fold them into paper with the thickness written on it. Not required for a KLR, but for a 4-carb bike I'd like them to be as close as possible.

If your bike runs fine you may never need to locate the washer. But it'll be either on the needle (under the clip) or not in the carb at all.
I know the washer can't escape by itself but remember......I took out the spring, white plastic thingy and the needle with the clip on it. Looked at it, fondled it, drooled a bit and put it back in. I am affraid the brass washer didn't come out with the needle and just hung out in the bottom of the slide. Then I go ahead and put the needle back in with the white plastic thingy, spring and cap it. Could the brass washer be caught under the legs of the white thingy and not letting it seat properly........or be rattling around next to the white plastic thingy?
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post #6 of 14 Old 03-11-2014, 04:43 PM Thread Starter
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Crisis aderted!!! I couldn't stand it so I shot home from work and took it apart again. Either I dropped the brass washer or it was never there.....either way it was not floating around inside the slide!!

Much appreciate the KLX needle education!!!

Many thanks!!!!
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post #7 of 14 Old 03-11-2014, 05:32 PM
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Quote:
Originally Posted by Delta Dog View Post
. . . but remember......I took out the spring, white plastic thingy and the needle with the clip on it. Looked at it, fondled it, drooled a bit and put it back in. I am affraid the brass washer didn't come out with the needle and just hung out in the bottom of the slide.
Ah. I didn't understand that you thought YOU dropped it.

My apologies.

Your solution, opening it up and looking again, solves it.
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post #8 of 14 Old 03-11-2014, 06:38 PM
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post #9 of 14 Old 03-11-2014, 07:39 PM Thread Starter
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Originally Posted by Grinnin View Post
Ah. I didn't understand that you thought YOU dropped it.

My apologies.

Your solution, opening it up and looking again, solves it.
No worries......I appreciate your insight on the issue. Very helpful.

Quote:
Originally Posted by DRB651 View Post
Thanks for the KLX needle link.......very helpful again. The brass washer ABOVE the clips seems goofy to me and seems to serve no purpose. Anyway, good stuff and I REALLY appreciate the genuine help and expertise so freely shared on this site!!!
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post #10 of 14 Old 03-11-2014, 07:46 PM
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Delta Dog:
I went out to my garage and measured the thickness of the factory "flange" on the top end of the factory needle removed when I installed the KLX needle kits in my KLRs. It measured .064" thick. I believe the brass washer HAS TO BE THERE to make up the difference in thickness from the C clip on the KLX needle to the thickness of the original KLR needle flange. If the brass washer is not there it will allow the needle to move up and down slightly between the top of the slide and the plastic spring retainer. The "plastic thingy" not only centers the spring, it traps and holds the needle in place firmly. The brass washer missing will allow the jetting to change randomly. Perhaps Tom or Willys could confirm or correct my thinking?
Best Regards....justjeff

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