The 22 cent mod is probably the most used mod for a KLR. Probably more than the Doohickey. Iam surprised to hear of this problem. This is the first time I have ever heard of a problem with the 22 cent mod. Don't know what KLR Double A has or if he has done anything else and don't know how the 22 cent mod was applied. You can bet Double A's 22 cent mod failure was not that of the KLR.
His bike is a 98' and completely stock as far as both muffler and airbox. It did start better for a couple days, but then he started getting backfires and it got hard to start. We swapped the plug out for a new one and it did the same thing.. Good, bad, nothing..
We undid the .22 cent mod, and installed another plug and it's been back to the original operation condition since.. That was early last spring that we did the changes..
The washer used in the .22 cent mod was the exact same thickness as recommended (checked it then, but I can't remember what the thickness was) but as I mentioned, when put back to original, it's ran like a champ since.
His 98' is a touch harder to start than my 02'.. He's more likely to need to use the choke than I am.. Once my bike has started for the day, I almost never need the choke, where his will if it sits for a couple hours..
On the other hand, his hasn't used a drop of oil in 22,000 miles, where mine always needs a bit after harder riding.