Need carb help - 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 16 Old 09-09-2010, 05:32 PM Thread Starter
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Need carb help

I have a 88 klr 650. I took the carb apart, cleaned it and put it back together. I cannot get the main jet to screw all the way in. Threads still showing. Not sure if it is supposed to or not. Bike is running terrible. Wont idle until very warm. Backfiring. Etc. I can't tell from the service manual. Can somebody send me a pic?
Thanks Again!!!!!!!!!!!!!
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post #2 of 16 Old 09-09-2010, 07:00 PM
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Dunno if you have stock Keihin carburetor main jet or not. Some will seat flush, aftermarket may have threads showing once seated. Lets suppose the main jet is set in place OK.




Sounds like your issue may be in the idle speed circuit. Do you have stock exhaust on the bike? Is the air filter in place, making a proper seal at the intake? If "yes" to both, try setting the idle circuit screw 2.25 turns out from gently seated. A too lean of a setting in the idle circuit will effect idle and may create deceleration popping. Popping can also be created from an improperly sealed exhaust system. More information regarding exhaust and air cleaner modifications are needed to make any exacting recommendations.


******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
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post #3 of 16 Old 09-09-2010, 08:56 PM Thread Starter
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Need Carb Help

My main jet is set just like the one in the pic. The air filter is new and properly installed. Have not checked the exhaust yet. Bike only has 7000 miles on it though. Still stock. Tried the 22cent mod. Didn't help although the bike had great throttle response through the entire range. When I turned the idle mixture screw to 2.5 turns, the problem got worse. Put a new plug in too. Checked the timing. It's right on. Changed all the petcock parts too. This whole problem started when the float stuck in the carb. I changed it and the bike hasn't run the same since. Measured the float height. It's right on. Just can't figure it out. Keep the info coming.

Thanks Again!!!!!!!!!!
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post #4 of 16 Old 09-09-2010, 09:23 PM
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Quote:
Originally Posted by dawgslife View Post
My main jet is set just like the one in the pic. The air filter is new and properly installed. Have not checked the exhaust yet. Bike only has 7000 miles on it though. Still stock. Tried the 22cent mod. Didn't help although the bike had great throttle response through the entire range. When I turned the idle mixture screw to 2.5 turns, the problem got worse. Put a new plug in too. Checked the timing. It's right on. Changed all the petcock parts too. This whole problem started when the float stuck in the carb. I changed it and the bike hasn't run the same since. Measured the float height. It's right on. Just can't figure it out. Keep the info coming.

Thanks Again!!!!!!!!!!

Choke stuck maybe, it's pretty easy to break the plastic sleeve on the carb or the cable is hung up somewhere?

Vent lines on the carb clear?

Does your carb have a coast enricher? Not sure how it works in relation to the low speed circuit (pilot jet and air screw) but somethings not right in that circuit.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 09-09-2010 at 09:29 PM.
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post #5 of 16 Old 09-09-2010, 10:21 PM
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Go back and make sure the diaphragm is seated correctly, is not ripped, or have hole in it. Usually this shows up when the carb moves off of idle... not at idle.

So far, this carburetor has had the float replaced, the enricher [choke] has been replaced. You later discovered the needle jet was missing. It has been cleaned a number of times. You've done the .22 mod. Maybe describe how that .22 mod was performed. That will take us to that diaphragm thing again. Usually if there is a problem in successfully completing that modification, the problem is found in the re-installation of the slide / diaphragm.

Back to the air filter. What brand of air filter? You said it was new, but have not came forth with WHAT BRAND? And was it oiled as instructed? This air filter thing can be very crucial. Some bikes do not run worth a tinker's dam with certain air filters.

The bike sat somewhere for 15 years. Have you checked the carburetor manifold boots with carb cleaner while the bike is running for air leaks? It is not beyond an unreasonable thought that the boots may have developed air leaks from cracks, etc. 15 years sitting can be worse than 15 years of being ridden.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #6 of 16 Old 09-10-2010, 09:59 AM
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Quote:
Originally Posted by vatrader View Post


Go back and make sure the diaphragm is seated correctly, is not ripped, or have hole in it. Usually this shows up when the carb moves off of idle... not at idle.

So far, this carburetor has had the float replaced, the enricher [choke] has been replaced. You later discovered the needle jet was missing. It has been cleaned a number of times. You've done the .22 mod. Maybe describe how that .22 mod was performed. That will take us to that diaphragm thing again. Usually if there is a problem in successfully completing that modification, the problem is found in the re-installation of the slide / diaphragm.

Back to the air filter. What brand of air filter? You said it was new, but have not came forth with WHAT BRAND? And was it oiled as instructed? This air filter thing can be very crucial. Some bikes do not run worth a tinker's dam with certain air filters.

The bike sat somewhere for 15 years. Have you checked the carburetor manifold boots with carb cleaner while the bike is running for air leaks? It is not beyond an unreasonable thought that the boots may have developed air leaks from cracks, etc. 15 years sitting can be worse than 15 years of being ridden.

You have privillaged info or are you clairvoyant?

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 09-10-2010 at 10:38 AM.
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post #7 of 16 Old 09-10-2010, 11:50 AM
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You have privillaged info or are you clairvoyant?
Just fortunate to have enough active cells to utilize the part of my brain that houses recall and memory. Not always optimally.

The OP has started five threads on this forum, four of which were relating to the fuel delivery system on this bike. I responded to each of those threads. I offered suggestions and proposed remedies to each posted carburetor related request for information and assistance.

A search of the OP's posting history on this forum should confirm what I have stated.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #8 of 16 Old 09-13-2010, 08:37 AM
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Quote:
Originally Posted by dawgslife View Post
My main jet is set just like the one in the pic. The air filter is new and properly installed. Have not checked the exhaust yet. Bike only has 7000 miles on it though. Still stock. Tried the 22cent mod. Didn't help although the bike had great throttle response through the entire range. When I turned the idle mixture screw to 2.5 turns, the problem got worse. Put a new plug in too. Checked the timing. It's right on. Changed all the petcock parts too. This whole problem started when the float stuck in the carb. I changed it and the bike hasn't run the same since. Measured the float height. It's right on. Just can't figure it out. Keep the info coming.

Thanks Again!!!!!!!!!!
Yo, dawgslife! Any success yet? We ain't out of bandwidth or ideas yet. keep us posted.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #9 of 16 Old 09-13-2010, 09:18 AM Thread Starter
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No Success Yet. I am beginning to thing it's something electrical. Is that possible? I may break down, load it on the trailer and bring it to a Kawasaki dealership for repair. Weather is awsome for riding right now. I want to ride!!!
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post #10 of 16 Old 09-13-2010, 09:39 AM
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where are you located? [roughly]?

The reason I ask is that I have had better luck with independent shops diagnosing and repairing situations like this than I have had at a franchised dealer. Often the dealer tech's experience is limited to maintenance, after market doo-dad installation and warranty issues, which in this day and age, come complete with a listing of wrench sizes and step by step process guide lines. Little need for investigative skills. A Japanese bike specialist might be the ticket.

I still believe your problems are in the carburetor. Achieving a balance. If you have a digital camera it might help some. Try to get us more history on this bike.....like, why was it parked way back when? Could there of been a mechanical problem, and they just walked away and left it sit? Are there any modifications on the bike that might lead you to believe that any jetting has been done? Is the air filter a Kawasaki air filter? Is the muffler a stock Kawasaki muffler? This is some critical information. If you have to pay someone to figure these things out, it could get spendy. They may opt to start replacing things until they hit on an answer. I don't like that to happen with my money. I like my money to go to gas and tires, not someone's guesstimate they bill for to the nearest decimal point.

Take a breath. Its only metal, plastic and textile. You can overcome it. Study what you are working with and get back with a detailed report of what you have.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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