Pilot Jet clear opening - 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 11 Old 10-07-2014, 10:43 AM Thread Starter
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Pilot Jet clear opening

I have removed and cleaned my carburetor. Learned how to by watching some great You Tube videos. When I was cleaning my pilot jet with a piece of wire, it would not go through from either end. I could see light but even the smallest wire would not slide through. So I figured that there must be an obstruction and I used a drill bit to clear it out. 1/16th fit easily in openings at both ends. But the obstruction was way to big to just be crud from gas and now I'm wondering if it was designed to have a constriction inside. Now that it is cleared, which took quite a bit of hand turning on the bit (I did not use a power drill), the opening is a clear 1/16th or so.....Did I screw up?
Thanks for your help!!
pete
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post #2 of 11 Old 10-07-2014, 04:19 PM
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Did you screw up??? Ya I think so.

Check this post and thread for some more info about pilot jet cleaning.

http://www.klrforum.com/showpost.php...64&postcount=3

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 11 Old 10-07-2014, 07:27 PM
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Originally Posted by pgrojean View Post
I have removed and cleaned my carburetor. Learned how to by watching some great You Tube videos. When I was cleaning my pilot jet with a piece of wire, it would not go through from either end. I could see light but even the smallest wire would not slide through. So I figured that there must be an obstruction and I used a drill bit to clear it out. 1/16th fit easily in openings at both ends. But the obstruction was way to big to just be crud from gas and now I'm wondering if it was designed to have a constriction inside. Now that it is cleared, which took quite a bit of hand turning on the bit (I did not use a power drill), the opening is a clear 1/16th or so.....Did I screw up?
Thanks for your help!!
pete
Well, these bikes are extremely easy to work on sooo, I would put it all back together and see how it runs. If it blows black smoke or stumbles when you goose it, you probably messed something up. Pilot jets aren't expensive so you won't be out much if you did mess it up.
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post #4 of 11 Old 10-08-2014, 07:18 AM
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Thought the pilot jet orifice was teeny-tiny; far smaller than 1/16" diameter.

Yet, since the idle mixture flow is metered by the fuel screw (i.e., idle mixture screw), maybe the too-big hole (if it is in fact too big) can be compensated for by fuel screw adjustment.
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post #5 of 11 Old 10-08-2014, 03:23 PM
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Off hand about a #74 number drill comes to mind but tend not to remember as just pull out an index. The ends are quite large, as you stated, but the center hole is tiny. Did you run the 1/16" bit all the way through? If so, you will need a new pilot.

HIH
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post #6 of 11 Old 10-08-2014, 04:25 PM
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Ya he did Norm from what I understood. Good thing they can be replaced.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 11 Old 10-09-2014, 06:45 PM
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An alternative might be to leave it in the carb with bad gas over the winter and see if the pilot gums up just enough....maybe not... ;-)

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Ya he did Norm from what I understood. Good thing they can be replaced.
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post #8 of 11 Old 10-10-2014, 11:18 AM Thread Starter
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OK, I get it! I screwed up. I thought I did when it took so much effort to work the 1/16" drill bit through the "obstruction". I'm going to buy a new pilot jet and not risk a 6000 rpm idle. Thanks for all the comments. Pete
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post #9 of 11 Old 10-10-2014, 01:14 PM
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The good side of this is that you now know more about the idle pilot than most owners. I find that these sorts of experiences provide a means to reflect and to increase understanding if employed. Might be a good time to go up a bit in pilot jet number?

The KLR is lean on idle at typical altitudes so find that a bigger pilot helps running. Can't recall the pilot number and no time to look in my notes but can do later although someone will hopefully have posted recommendations by then.
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post #10 of 11 Old 10-10-2014, 02:00 PM Thread Starter
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Interesting last comment...I just went to local "Extreme sports" shop to find new pilot jet (40). They didn't have a 40, only a 38 which they said would probably work just find. He also recommended that I back out the screw 3 turns to open it up as much as possible....what do you think?
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