KLR650 C, mods questions - 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 5 Old 10-10-2015, 07:04 AM Thread Starter
Join Date: Sep 2015
Posts: 13
KLR650 C, mods questions

hallo guyz, George from here Greece and i have a few questions about my KLR. As soon as We dont have many KLR in Greece ( we have yamaha Xt instead ) i was looking forums for informations in other countries and im glad i found urs.

Anyway im gonna make a small presentation about my KLR

Exhaust : Arrow totally free exhaust. ( probably the previous owner had an Larger Arrow exhaust cutted and fitted on KLR with many mods. Exhaust is WAY TOO LOUD. I even made a home made silencer but still.... )

Carb : CVK 40 , Drilled a hole 7/64 as many of u suggest ( i was even doing this mod in my other bikes with CV carb so i am quite familiar with it . Main jet 150 (from previous owner ) no 22 cent mod, no klx needle.

Snorkel removed.

No holes into airbox

Engine completely stock

Thats all about the engine.

Some questions now:

( i wanna make clear that its allmost impossible to find Stuff like klx needle, DJ kit, Schnitz 685-705 kit, Eagle Mike Doo-Hickey ** c models dont have that problem like A-B models for USA** , FMF-Big gun exhausts, K&N - UNI FOAM filter in Greece and general in Europe. So i need to gather information to make a BIG order from USA about stuff i need to change. )

1. My bike burns oil, from the stuff i have read online allmost all Klrs does that and the only solution is aftermarket piston ( i am right ah? ) . So my 1st question is this
Schnitz racing piston kit 685 ( order from usa ) VS Wossner 101-102 mm ( can be pursuased from Greece).

2. CV vs Flat slide carb. As i said before, i am familiar with CV carbs. thaugh the question is this. **I can get in my hands a Mikuni tm40, a dellorto PHM 40 ( from ktms i guess ), FCR mx 39-41.**
Does it worth to put on a Flat slide carb or modify the CV ( prolly with KLX needle, and from that baseline, cause of free exhast to play with various MJ and L mode on airbox. ) Have heard tha the power difference with a Flat slide pumber carb is way better on 1 cylinder engine even 3-5 HP if tuned correctly

3. Atm my bike probably is way to lean even with 150 MJ. It pops a lot in deceleration.

those are the following reasons i guess

Stock bike allready lean
Free pipe makes it even leaner
Snorkel removed makes it even leaner

atm im using some ducktape instead of snorkel ( as soon as the previous owned had it removed ) and the pops at deceleration seems a bit better now , it aint gone still there but way better.

Is there something i can do for pops till i decide what option to choose ( upgrade CV or go for Flat )??

Thats all guyz, I need to say a big thanks in advance for ur time reading this. Any tips are so welcome. ( and so sorry about my bad english since its not my mother language )

Wish i could attach some photos

With regards,

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post #2 of 5 Old 10-10-2015, 07:40 AM
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Join Date: Feb 2013
Location: Maine
Posts: 368
Many KLRs burn oil. Mine did. People disagree about the most common reasons. Rings. Cylinder liner ovalizing. Valve-guide seals worn, hard, or cracked . I did the whole array to solve the oil use and reduce future oil use. I chose the Schnitz 705 piston (103.89mm, made by DP Pistons) which required a new liner (made by LA Cylinders) and gives a nice torque boost. I would have no trouble ordering Wossner myself. The Schnitz kit was handy with one problem they took care of very quickly (DP put radically wrong rings in the box).

There's enough chatter about ovalized sleeves that my long-term goal was to have a thicker sleeve. Other pieces followed from that.

But the solution for yours COULD be as easy as replacing valve-guide seals. Leakdown test will tell you for sure. You didn't mention the year of your bike so I don't know if yours have aged or not.

I happen to like CV carbs although I have bikes with pumpers and cable-slides (no flat-slides). Pumper carbs do help acceleration but CV remain (mostly) in tune with elevation changes. I see that you've drilled your slide so you're more interested in quick response than I am.

Popping on deceleration is probably not caused by the main jet. When you close the throttle, the mixture is controlled more by the pilot jet or the needle and needle jet depending on how far you close the throttle. The main jet controls WOT mixture although it will change mixture at other openings a little bit.

It COULD be that your bike is lean at WOT too, but that's not indicated by popping on decel. I've futzed with a few exhausts on my KLR including packed mufflers where the mixture changes as the packing departs. I'm now back to a stock muffler which is easy to tune the carb to and it doesn't change during a month of riding. (But the Leo Vince is back on the market.) I want quiet so my preferences may not be yours.

Last edited by Grinnin; 10-10-2015 at 07:42 AM.
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post #3 of 5 Old 10-10-2015, 08:54 AM
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Location: Fort Sask , Alberta, Canada
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Welcome to the forum Neuton. Always good to hear from someone overseas. We hear a lot about Greece in the news these days.

As to the ability to post photos. As you are likely aware we require 15 posts before a user can submit pictures. This is done as an anti-spam measure. There are a couple of options around it. The best option is to post your pictures to a site like Photobucket and then forward the link(s)in a Private Message to a Moderator who can insert them for you.

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post #4 of 5 Old 10-10-2015, 09:23 AM
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Join Date: Jan 2011
Posts: 4,706
Minor "popping" on deceleration isn't a serious problem, in my view.

One cause COULD be, a defective air cut valve/coasting enricher/backfire preventer (all names for the same carburetor component).

Some really terrific videos, and a link to a really terrific article on the CVK40 can be found on this website.

Drilling the slide affects only throttle response; adjusting the idle mixture screw (must remove anti-tamper plug to get to it) may solve some deceleration backfires, with a 50 main jet and a stock needle, high-end mixture might be rather fuel-rich.

My opinions only; other exist just as valid.
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post #5 of 5 Old 04-15-2016, 03:45 AM
Join Date: Oct 2015
Location: Manchester UK
Posts: 2
Hi guys -'im new on this forum - but have a 2001 KLR650 C model - I have bought an eagle mike klx carb kit - but not sure what setting to set the needle clip at - Eagle Mike says he's not sure about C Model as they don't have them in the states.

I have 140 142 and 145 jets to chose from. I read an article from someone who had solved this - but I can't find the article since.

Anyone got any ideas on what might be the right clip setting on the needle?

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