Jetting and Carb Tune 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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  • 1 Post By Back2Kawi
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post #1 of 6 Old 04-12-2016, 07:03 AM Thread Starter
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Jetting and Carb Tune Question

Hi guys,

I inhereted a 2002 KLR with 40,000 km, and it's had a history. Painted a sexy blue and gold with a bizarre mod list (you should see the subframe bolts), I rode the bike all last summer and noticed the carb was gummy and sluggish.

I'm giving it an overhaul for the summer - doohickey, carb tune, general maintenance and recommended mods - and I'm a bit puzzled on how to tune my carb.

So far I've done:

- Dynojet kit (already on the bike when I got it)
- SuperTrapp IDS2 (already on the bike)
- Cut and de-snorkeled airbox
- Pine-Sol soaked and cleaned the carb
- Drilled mixture screw (2 1/4 turns)
- Drilled slide to 7/64

What puzzles me is the jetting on the carb. It's got a Dynojet #150 main (Keihin #165 according to JetsRUs) - I've never seen someone mention anything higher than #150 Keihin. On top of that Dynojet says stage 2 (third notch on the needle) is supposed to go with a #155 jet (Keihin #171).

I'm gonna test the new setup tonight, but I've never heard of jets this big used on the KLR. Right now I'm leaning toward the #155 jet as prescribed. I'd really appreciate some pointers on where to go.
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post #2 of 6 Old 04-12-2016, 08:18 AM
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Plenty of people on here use a 150 dynojet main jet for a stage 2. Also dynojet jet sizes are their own number system. Your carb may run fine after its cleaned with that 150 jet.
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post #3 of 6 Old 04-12-2016, 11:01 AM
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Yes to the above, everyone who has a dynojet seems to be in another world when speaking about tuning etc etc just because we all use stock jets etc etc and simply go up a jet size or two. IMHO, if you are wanting to keep the bike and are having serious issues with the jetting tuning after a solid cleaning dismantling etc etc, I would swap it out, try and sell the kit on fleabay and buy the KLX kit from Eagel Mike.....it is like talking apples and oranges I'm afraid when this single topic is sked about....yes ther has to be people out there who can easily help you.....but the general owner knows stock jet sizes and what is recommended. sorry to be a dick...but hey.....
Oh and welcome....this is a great site by the way.

Willys
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post #4 of 6 Old 04-12-2016, 11:03 AM
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As I said "elsewhere";

The DJ kit is WAY too rich; the needle is fine but swap to a 142 KH main. 2nd position, no washer under, 2 turns on the fuel screw and drill the slide 7/64th if you wish.

My 2001 has the DJ needle and is jetted as above and my 2000 runs the KLX kit with the same settings; they both run and are jetted perfectly and this set-up has been proven out on an AF meter.

Cheers,
Dave
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post #5 of 6 Old 04-12-2016, 07:03 PM
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I went with the DJ 140 following the stage 1 instructions. Seems to run very good for my bike.


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2003 KLR 650
Cogent suspension front and rear, jet kit, Lexx pipe, Uni filter, D606 tires
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post #6 of 6 Old 04-13-2016, 03:18 PM Thread Starter
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Thank you all for the advice!

Quote:
Originally Posted by DPelletier View Post
swap to a 142 KH main. 2nd position, no washer under, 2 turns on the fuel screw and drill the slide 7/64th if you wish.
Dave, thank you for the super helpful procedure. Ran the bike last night with a #150 Keihin, 7/64 slide, 2nd position on the needle and 2.25 turns on the fuel screw, and it was a whole new beast - I couldn't be happier! Gonna adjust the fuel screw and get a #142 jet, then keep adjusting.

Cole
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