Refitting carb - 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 8 Old 04-26-2008, 06:06 PM Thread Starter
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Refitting carb

Hi All,
I got the carb on my 650 KLR all cleaned up and back together while still on the bike. Thought it wouldn't be too hard to get it back inbetween the airbox and head...think again...didn't go like I planned. So, does anyone have an easy way of doing this? What should I remove first? Don't want to start taking things off until I know if there's an easier way. Help please!

Bob
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post #2 of 8 Old 04-26-2008, 10:26 PM
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I have never taken mine off, but I am pretty sure you need to remove the subframe and the airbox to be able to mount it back correctly. I am sure someone that has had theirs off will give better advice if I am incorrect.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 8 Old 04-27-2008, 08:47 AM
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You could just remove the upper subframe bolts and allow it to tilt back pivoting on the lower bolts.

This would be a good time to inspect that area for a tight fit and cracks and consider replacing the bolts with 12.9s.

The upper bolts may have RED loctite in there so it would be a job getting them loose.

Watch the battery ground cable. If it stretches too far it may break behind the starter motor & headpipe. A pain.

Good luck.

John

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post #4 of 8 Old 04-27-2008, 10:29 AM
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Install the carb in the manifold then gently pry the aircleaner tube around the rear of the car with a screwdriver. Very easy to do and you do not need to remove the subframe.
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post #5 of 8 Old 04-27-2008, 06:08 PM Thread Starter
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Vezi,
I must be missing something. How do I install the carb in the manifold with the aircleaner tube in the way like it is? If I could just slide it it in I'd be one happy Kawboy!

Bob
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post #6 of 8 Old 04-27-2008, 06:45 PM
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Push the carb in the manifold while holding the aircleaner hose to one side. It's easily bent and then pry the hose over and around the rear of the carb.

Last edited by Vezi; 04-27-2008 at 07:24 PM.
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post #7 of 8 Old 04-27-2008, 07:15 PM
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KAWBOY!!!! gotta luv it.

Like one of the ol' timers here posted KLR = Kawasaki Large Riders.

Last edited by BIGIRON; 04-27-2008 at 07:36 PM.
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post #8 of 8 Old 04-27-2008, 08:41 PM Thread Starter
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OK, I used abit more force and put the darned thing back together. Put the tank on hooked it up and started it up and let her warm up. Went for a short test ride down the block and around the trees and all seems good.

Thank you Vezi and also the others who replied.

One happy Kawboy,
Bob
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