Under 1/4 Throttle weak - 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 6 Old 07-05-2017, 12:36 PM Thread Starter
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Under 1/4 Throttle weak

Bike otherwise runs good but throttle under 1/4 is pretty weak and there is a noticeable jump from under 1/4 to above where it runs good. I've tried shimming the needle with a washer, I've tried adjusting the fuel screw (1 turn, 2 turns, 3 turns... nothing works) I have stock exhaust, airbox, air filter. Air filter is clean, chain is clean, fuel is good.

Any help appreciated, thanks!
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post #2 of 6 Old 07-06-2017, 06:40 PM
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Quote:
Originally Posted by Jared650 View Post
Bike otherwise runs good but throttle under 1/4 is pretty weak and there is a noticeable jump from under 1/4 to above where it runs good. I've tried shimming the needle with a washer, I've tried adjusting the fuel screw (1 turn, 2 turns, 3 turns... nothing works) I have stock exhaust, airbox, air filter. Air filter is clean, chain is clean, fuel is good.

Any help appreciated, thanks!
Jared650,
I guess we have all thought about your question for a day. You are pretty short of overall information.

Here is my best guess. At the bottom edge of the throttle plate there are 3 or 4 small pilot outlet holes which get their fuel from the pilot jet, same passageway feeds the adjustable mixture screw. I'll suggest that one or more of those holes is either plugged or restricted. I use a tiny wire bent at 90 degrees to poke down thru those holes, with pilot jet removed of course. Then back-flush with aerosol carb cleaner and compressed air to blow the crap back out thru the way it came in.

The pilot jet, mixture screw and those 4 holes have primary fuel control to about 1/4 throttle.
Good Luck.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 6 Old 07-06-2017, 07:22 PM Thread Starter
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I'm not really sure what else to tell you, I did the .22 mod (didn't drill the slide) and turned the fuel screw out to 2 turns because I was running lean and had some surging at light throttle. After I did this mod I was left with a very weak 0 - 1/4 throttle but the rest of the range is good.

I will take the carb out and clean it very thoroughly, thank you.
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post #4 of 6 Old 07-06-2017, 07:26 PM
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Read this also, Care & Feeding Of The Keihin Carb

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 6 Old 07-06-2017, 08:48 PM
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Originally Posted by pdwestman View Post
And this, if you plan on cleaning your carb:

http://www.klrforum.com/how-tos-tech...-overhaul.html
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post #6 of 6 Old 07-07-2017, 08:29 PM Thread Starter
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Thanks for your replies. I watched the videos and overhauled the carb. I did discover that the washer I put on the needle was too large in diameter and was holding up the white 5 pronged thing that goes inside the slide. I'm pretty sure this was my problem.

Runs great now!
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