Carburetor Help - Unable to Cold Start After Rebuild - Page 3 - 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 #21 of 40 Old 04-30-2020, 10:32 AM
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Quote:
Originally Posted by Eric Frazier View Post
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
Credit to Tom Schmitz for adding that fine pic to my description.

The float bowl atmospheric air vent that originally had a 'pinkish' hose connected to it is the Upper Left plastic nipple on the carb. Same style as lower rearward fuel nipple.
Originally that hose dangled behind the engine, alongside the shock spring.

But when people crossed deep water too slowly the water would block the hose & the engine would die.
Solution, install a 'T' fitting, upside down, directly behind the carb air vent fitting and run a second air vent hose up alongside of the large frame spine towards the steering neck and tuck it back down into the LH front corner of the gas tank mounting puck steel box.

The Gen 2 bikes just lay the air vent hose on top of the air box, alongside the RH sub-frame pipe. Just waiting for water to run down inside of it & into the carb. I at least re-route the Gen 2 hose so that can't happen.

pdwestman
Modify at "YOUR OWN RISK"!

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post #22 of 40 Old 04-30-2020, 10:33 AM Thread Starter
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Okay, thanks Dave! That makes sense. Wasn't sure with the different sizes on the new jets but decided to go with the original stuff since it cleaned up so well after the soak in the Berry's carb cleaning solution. I mean, the stock setup worked well before my fuel went bad and screwed up everything!

I've got the carb back on the bike. Just waiting for my son to wake up to help me push the subframe up so I can get the crash bars and subframe bolt lined up. While everything was out of commission, I decided to go ahead with the EM drill-through subframe bolt modification. I've had it laying around for five or six years but was afraid to undertake drilling thru the frame until now. It went well: I didn't have any issues with the mod. Should have done it sooner! I did make the mistake of inserting the subframe bolt from right to left so I had to remove the entire bolt to get back at the carburetor. I'll correct that as soon as I can wake my son up to help me out!

Eric
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post #23 of 40 Old 04-30-2020, 10:54 AM Thread Starter
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PD,

Oh, okay. I see what y'all are talking about now with the vent line. Yeah, that's all clear. In fact, I pulled it from the frame the other day contemplating doing the T mod. I bought some vinyl tubing and a T-fitting the other day at Home Depot when I was getting tubing to check the float level using the drain method. I realized that the tubing only had a temperature rating of 70F so I'm not sure that'll work or not for that application...
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post #24 of 40 Old 04-30-2020, 11:04 AM
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Originally Posted by DPelletier View Post
Gen1's use a 148 main and Gen2's use a 150 IIRC.....with the stock needle, of course.

Cheers and good luck

Dave
Actually the Gen 2 bikes came with a #145 Main Jet. The EPA snorkle restricted KLX650-A1 came with #135 Main Jet.

I do not find EM to sell a Carburetor Rebuild Kit for either generation of KLR's on his parts screens.
Only KLX re-jet kits, with KLR650 sized main jets.

So now I truly question what Eric Frazier even has for a needle. Non-adjustable or adjustable with circlip?
A true KLX650, circlip adjustable, needle has the ID # N1TB stamped into it, find a 10X magnifying glass, Eric.
An OEM Gen 1 non-adjustable needle has ID # N31R. (Just under the button head or circlip grooves, Eric.)

Non oem rebuild parts kit needles probably do not have any ID #.
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pdwestman
Modify at "YOUR OWN RISK"!

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post #25 of 40 Old 04-30-2020, 11:57 AM Thread Starter
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Mission Accomplished!

Thanks! Thanks! Thanks, for all the help! It started on the first application of the starter! Couldn't be happier! Mission Accomplished!

PD, what do I need with a magnifying glass? That's what I got kids for: just gotta wake them up first! No, seriously, the needle from EM is brass colored and is stamped "D567". That's the only marking I see. link for the Carb kit I ordered from EM. I didn't see it on the '87-'07 page but it shows up when I search it. I tried to post the link but received an error that said I needed 15 posts to post a URL.

Anyway, thanks again to everybody for your help on this! Gotta go button it up and take it for a ride...

Eric
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post #26 of 40 Old 04-30-2020, 12:43 PM
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Quote:
Originally Posted by pdwestman View Post
Actually the Gen 2 bikes came with a #145 Main Jet. The EPA snorkle restricted KLX650-A1 came with #135 Main Jet.

I do not find EM to sell a Carburetor Rebuild Kit for either generation of KLR's on his parts screens.
Only KLX re-jet kits, with KLR650 sized main jets.

So now I truly question what Eric Frazier even has for a needle. Non-adjustable or adjustable with circlip?
A true KLX650, circlip adjustable, needle has the ID # N1TB stamped into it, find a 10X magnifying glass, Eric.
An OEM Gen 1 non-adjustable needle has ID # N31R. (Just under the button head or circlip grooves, Eric.)

Non oem rebuild parts kit needles probably do not have any ID #.
Thanks; I knew that - don't know what I was thinking.

Yes, this all boils down to what needle he is using - to make it dead simple, I'd just ask does it have the adjustment grooves on the top or not? ....knowing that would give us a pretty good idea

Dave
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post #27 of 40 Old 04-30-2020, 12:45 PM
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Maybe this will help;

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post #28 of 40 Old 04-30-2020, 12:46 PM
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another KLX needle pic;


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post #29 of 40 Old 04-30-2020, 12:47 PM
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Like Paul, I didn't realize EM had a stock rebuild kit but here it is;

https://www.eaglemike.com/Carb-rebuild-kit-CRK.htm
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post #30 of 40 Old 04-30-2020, 12:57 PM
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Hmm. Sumo uses needles with a DXXX marking, but the ones I have for a CVK40 are marked D642.

The #150 main jet and the #38 pilot still confuse me.

Glad it is working out though!
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carb, carburetor, cold starting, hard starting

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