Carberator changes? - 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 10-29-2018, 06:39 AM Thread Starter
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Carberator changes?

Hi guys, new to klr’s and mine run like crap at part throttle. Almost impossible to start cold. All new valves shimmed properly. It was missing the KACR spring so I ordered and installed a new one. Found the previous owner had pried on the carb when he rebuilt it breaking the mixture screw boss off and he put it back on with jb weld. Plus the choke cable plastic piece is broke too. Been looking for a new carb and it appears the carbs are the same till about 2007. Hate to buy a newer carb if it won’t work, but already got one off a supposed 85 and it was for a 250 and so corroded inside it was unusable. Thanks for any help. Just trying to bring a bike back to life that hadn’t run since 2001.
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post #2 of 6 Old 10-29-2018, 09:05 AM
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It's too lean
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post #3 of 6 Old 10-29-2018, 10:02 AM
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I believe any and all KLR650A and E carbs will work; there were some minor changes in 2008 and 2012 IIRC.

As far as the enricher nut goes; a cracked/broken one can cause a lean condition. You can buy a replacement at Artic-Cat (PN 5507-025) for cheap. Alternatively, Stead engineering makes a brass replacement that will outlast the bike.

Beyond that, make sure the carb is clean (when you think it's clean, clean it again!) and that the jetting is right. Stock jetting will work OK as long as everything else is stock, otherwise pick up a KLX jet kit from Eaglemike and the bike will run better.

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post #4 of 6 Old 10-29-2018, 11:43 AM
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Agree . . . to the best of my knowledge and belief, any Keihin CVK40 carburetor will fit and work on any KLR650; corrections and clarifications welcomed from the cognoscenti.
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post #5 of 6 Old 10-29-2018, 12:14 PM
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Sounds like an idle circuit issue. The idle circuit can be a bit finicky. There are three small holes near the throttle plate that feed the bike at idle and part throttle. These need to be clear and may need a bit of poking with a fine copper wire. Verify that they are clear by spraying carb cleaner in through the idle jet and looking for fluid coming out of each of the small holes.

For general CVK cleaning and service, watch these videos:

For the enricher valve (choke), consider a Stead unit.

This broken boss for the idle screw, how broken is it? Was it a case of the shroud being sheared away or was the whole boss, threads and all, sheared away? Got pictures? You can PM them to me or PM a link to them and I'll get them posted for you.

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post #6 of 6 Old 10-29-2018, 05:03 PM Thread Starter
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Thanks guys, I’ll be ordering a newer carb now. And when I said he broke it off, I mean completely broke it off past the threads
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