Weekend repairs - 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 3 Old 06-19-2017, 07:30 PM Thread Starter
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Weekend repairs

So this weekend I was doing a couple of repairs and mods to my 92, KLR. Just as I was putting all back together I did a quick carb clean everything went well. I went to install the choke cable and the spring fell off of the cable that goes in my carb. Thats problem #1,now I thought I could jerry rig it with a ball point pen spring or something similar it didn't work. So I gave up and ordered 3 of the springs from partzilla. Now I wanted to make sure everything was all good with my carb so I went to try and hook the fuel lines up to the tank and it wouldn't start. I took out my cable after the video I've attached and tried using a tooth pick and still to no avail it wouldn't start back up. I got it to crank once out of the multiple times
. I started asking around and my dad said it it sounds like its not getting any gas so problem #2. Now I feel Like I don't have my fuel lines hooked up correctly I can add a picture of the hoses and have them circled if it helps. I've checked around for fuel diagrams and in service manuals no luck. Thanks in advance for saving my ass guys!!

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post #2 of 3 Old 06-20-2017, 04:12 PM
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Hope it is usefull.
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post #3 of 3 Old 06-21-2017, 11:03 AM
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Recommend service manual, and/or visit to competent shop or consultation with knowledgeable individuals.

Easy to tell whether your carburetor is receiving gasoline: After cranking engine for awhile, open carb drain screw (at bottom of carburetor float bowl, 3 mm Allen (hex) key required on later-model KLR650s) to see if any fuel flows out.

You must crank your engine first, because . . . the petcock is vacuum-operated; engine vacuum must activate petcock for fuel to flow. A vacuum hose connects the petcock to a port on the carburetor.

The "CARB OVERHAUL" and the "CARE AND FEEDING OF THE CVK40" threads elsewhere on this website provide valuable fueling information.
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