Carburetor Help - Unable to Cold Start After Rebuild - Page 2 - 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 #11 of 40 Old 04-28-2020, 11:00 PM
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Have you shot stuff through the low-speed air-jet and are the emulsion tubes all clear?

Do what Paul suggests with the enrichener jet.

I presume that the bowl vent line is free and clear, the diaphragm is properly installed and has no holes or tears, the vacuum ports are either connected or capped, the exhaust header is tight, the intake manifold bootie-thing is screwed-down tight and the clamps at both ends of the carb are properly situated and tightened.

If the inlet valve were not sealing against the seat the carburetor would be flooding. That said, if you want to clean that seat you can do so with a cotton swab and a bit of metal polish.

What's this about a 150 main jet? Why did he give you a new main jet and is it a Keihin 150?

Maybe you should take a look at your valve lash. Everything points to 'your bike should start just fine'.
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Last edited by Tom Schmitz; 04-28-2020 at 11:02 PM.
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post #12 of 40 Old 04-29-2020, 04:03 AM
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Hi,

I had this issue.
From the original post sounds like the only thing not working is the choke/enricher.

I had air leak here preventing rich mixture for start up-the plastic fitting is easily damaged.

hope you get sorted
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post #13 of 40 Old 04-29-2020, 04:31 AM
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Suggested desperate lunge:

Re-install previous jets.

Even, . . . old enricher probe, if changed.

Was needle changed; slide drilled? If so, might put old needle back in; slide hole should not affect starting (IMHO).

Hey, I SAID it was desperate!

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post #14 of 40 Old 04-29-2020, 09:59 AM
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Originally Posted by Eric Frazier View Post
All,

It does seem to idle well wherever I set the idle speed at.

I do have the carb off the bike and disassembled again now. I will see what I can do with the ports on the enricher circuit. Not quite sure how to get at it...

Everything I've looked at so far looks clean to me. I've passed a .025 and .06 wire thru the passages on the carb body without any issue. It all looks clear to me. Looks like maybe the bowl seat of the float valve could use a little more attention. Any suggestions on how to best clean that?

I also noted that the main jet that Eagle Mike supplied is a 150. The stock size I removed was a 148. Also, the EM supplied pilot jet is a 38. The OEM one I removed was a 40.


Any other suggestions while I'm I've got it torn down would be welcome as well.

Thanks again, Eric
While it isn't likely your problem, those jet sizes are weird. EM's KLX kit comes with a 140, 142 and 145. It doesn't come with a pilot jet and most use the stock 40 or a 42....I'm confused as to why he would have sent you those jet sizes?

you can't compare the stock main jetting using different needles as the KLX needle itself runs richer - in any case, I'd guess your pilot is way too small (you'd need more than 2 turns!) and your main is too big (rich). Make sure you've pulled your airbox snorkle too.


Dave
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post #15 of 40 Old 04-29-2020, 03:31 PM
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The non-removable cold start jet is the brass orifice next to the main jet & pilot jet tower. Its passage feeds fuel up to the brass plunger connected to the cold start cable.


@pdwestman

Credit goes to Tom Schmitz for adding this pic and labels.

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Last edited by pdwestman; 04-30-2020 at 10:13 AM. Reason: Thanks Tom.
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post #16 of 40 Old 04-29-2020, 06:07 PM
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Check the posts in the Gen II section regarding carb problems on a 2009.
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post #17 of 40 Old 04-30-2020, 01:12 AM Thread Starter
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Hey everyone,

Here's an update on my progress...

Tom, I was able to actually pick a 1st string from my brother's Stratocaster! I used it to verify the four idle circuit and enricher circuits were open. Last night, I submerged all the metal parts in Pinesol and a mix of very hot water and let that soak overnight. I bought a gallon of Berryman Chem-Dip Carburetor Parts Cleaner this morning and soaked everything in that today. I Afterwards, blew out all the passages, paying special attention to the idle and enricher circuits. Thanks PDWestmanon for the detailed labeled diagram of all the passages. That was very helpful identifying everything I needed to know!

All the passages and emulsion tubes are clear, the vacuum ports are connected. I used some Brasso and Q-tips to polish the seat of the float valve because it looked a little rough and I missed it the first time. I also used those to remove the build-up and polish out the slide: Don't know how much good that will do but it sure came out looking real nice!

The exhaust header is tight, the intake manifold is secure, and the carb clamps will reinstalled and tightened correctly. Tom, I'm not sure what you're talking about by bowl vent line. Is that what I've been calling the overflow vents (the two openings in the top of the bowl? If so, those are clear. The bowl gasket is new and in good condition.

I don't know why Eagle Mike sent me the 150 main jet and 38 pilot jet in my carb rebuild kit. I thought the listing on his website said it was for the stock set-up. I didn't look at the sizes when the parts arrived: Hell, I can't even see the small type anymore anyway! I had just assumed it was the correct size. Tom, I don't see the Keihin "K" on them Jets. I'm not certain what make they are. They only have the size stamped on them in three places around head. Maybe he sent me the wrong size with the kit by mistake or maybe I ordered the wrong kit... I don't know. I just ordered directly off the website: I didn't talk to him personally on the phone. I'll reach out to him and see what the story is.

Anyway, since I've cleaned up all the original parts (148 Main & 40 Pilot Jets) and they look real good to me, I plan to reinstall the old parts to eliminate improperly-sized jets as a cause for the irregular starting. I'll just hang on to the new parts from the kit until I can find someone who can use them, I guess.

I feel like I've done everything I know to do. I plan to reassemble the carb and reinstall it on the bike tomorrow to see how it behaves. Please let me know if you think of something else or if you think I should try something different. I surely appreciate everyone's helpful suggestions so far! Thanks for your time and effort: I'll let you know how it turns out this time around...

Thanks, Eric

Last edited by Eric Frazier; 04-30-2020 at 07:00 AM.
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post #18 of 40 Old 04-30-2020, 08:10 AM
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Quote:
Originally Posted by Eric Frazier View Post
Tom, I'm not sure what you're talking about by bowl vent line.
The vent line is the clear-pinkish tube that attaches to a nipple on the upper left side of the carburetor; at least it is on a Gen II.

If the engine ran for more than a few minutes you don't have a vent problem. Similarly if the engine would idle properly you don't have a "guitar string port" problem.

I think Paul is on the right track with his suggestion: I'll suggest that possibly the non-removable cold start enrichener jet needs the guitar string pushed thru it & blasted with carb cleaner & compressed air. Pulling the handle opens the air port, but varnish must be blocking the cold start fuel jet. So technically it is leaning the mixture, rather than enrichening the cold start mixture.

At this point I would focus on to the cold-start enricher jet, making sure it is clear, and pay careful attention when reassembling and installing the carburetor.

Good luck!

Jason
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post #19 of 40 Old 04-30-2020, 08:40 AM Thread Starter
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Jason,

I guess the Gen 1 carb doesn't have that feature. I don't see anything that looks like that at all. I went back and worked on the enricher circuit one more time. I feel confident it's clear. I'm gonna go ahead and put it back together. Thanks for the encouragement!

Eric
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post #20 of 40 Old 04-30-2020, 10:12 AM
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Quote:
Originally Posted by Eric Frazier View Post

I don't know why Eagle Mike sent me the 150 main jet and 38 pilot jet in my carb rebuild kit. I thought the listing on his website said it was for the stock set-up. I didn't look at the sizes when the parts arrived: Hell, I can't even see the small type anymore anyway! I had just assumed it was the correct size. Tom, I don't see the Keihin "K" on them Jets. I'm not certain what make they are. They only have the size stamped on them in three places around head. Maybe he sent me the wrong size with the kit by mistake or maybe I ordered the wrong kit... I don't know. I just ordered directly off the website: I didn't talk to him personally on the phone. I'll reach out to him and see what the story is.

Anyway, since I've cleaned up all the original parts (148 Main & 40 Pilot Jets) and they look real good to me, I plan to reinstall the old parts to eliminate improperly-sized jets as a cause for the irregular starting. I'll just hang on to the new parts from the kit until I can find someone who can use them, I guess.

OK, I think I got it; I was assuming you got a KLX jet kit from Eaglemike but it sounds like you got a stock rebuild kit instead? .....that means you are still using the stock needle? If so, the jet sizes make more sense though it wouldn't hurt to put the original jets in as there isn't a ton of difference. As I said in my last post, the KLX needle itself is a richer taper so it needs a leaner jet.....the needle and jet work together and you can't compare jet sizes directly using two different needles. Gen1's use a 148 main and Gen2's use a 150 IIRC.....with the stock needle, of course.

Cheers and good luck

Dave
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carb, carburetor, cold starting, hard starting

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