Join Date: Dec 2019
Location: West Central Canada
Often the little rubber seal on the plastic nut holds up the cable, make sure its seated and check the free play on the choke cable
People often miss checking the air jets are clear when cleaning the carb. THey are at the back of the venturi (air box side) and flow into the pilot and main jets which both feed into the venturi. Also check the little holes on the side of the needle jet (main jet screws into the needle jet)
The little by pass holes at the bottom edge of the throttle plate can be chased with a stripped twist tie if you haven't already.
A bad plug or plug with a squashed gap will make a machine run as described. sb 0.035" (plugs will last the life of the machine for MOST people, although the KLR will go long enough to need a plug change eventually. re gaping occasionally is required) you may want to put the old, known good, plug back in.
Float Stuck? if the bike sat with fuel in it maybe the needle n seat aren't sealing?
No mouse nest in the air box or exhaust ?
you can either buy a block off kit for the vacuum tap to convert it to manual, or PM me and i'll show you how to do it with NO parts.
Just a few thoughts .... May seem like i'm being obvious, but just making sure nothing is missed, no offense intended.
Last edited by KLR Jo; 12-29-2019 at 10:07 AM.