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post #1 of 4 Old 02-19-2013, 06:45 PM Thread Starter
Join Date: Feb 2013
Location: Timmins ON Canada
Posts: 13
Question KLX Needle Jetting Question

Hey Guys,

I bought a KLX needle kit and it's going to be my first time working on any type of carburetor I have a few questions regarding jetting. First off the mods I have done to my bike so far are:

- UNI air filter
- pulled the snorkel
- drilled out the stock muffler baffle and put and HMF cap on it

OK the first question is in what configuration do I install the needle, is it clip in second slot with the brass spacer on top and a washer underneath? or are the washers included in the kit just for fine tuning?

What jet would you guys recommend for my bike in it's current configuration? I may do the L-Mod at some point as well. The kit comes with a 140, 142, and 145 jet. I think I read somewhere that the 08 KLR comes stock with a 145 jet would it be OK to leave in? I bought a 142.5 jet separate but it looks a lot bigger than the jets that came with the kit I'm thinking I received the wrong part.

And finally how many turns out should I adjust the mixture screw?

Thanks in advance for the help.
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post #2 of 4 Old 02-19-2013, 07:01 PM
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Join Date: Feb 2009
Location: Redondo Beach
Posts: 8,082
Here are the general instructions, courtesy of Schnitz Racing:

KLX Needle Kit

For 1987-2008 KLR650

Assembly Notes:

• The small brass collar/spacer goes above the circlip. Do not install it below the circlip. It will make the bike too rich.
• Needle clip position numbers are counting from the top down. The top or #1 position, is full lean. The lowest position, or #5, is full rich.
• Be very careful not to damage the carb slide diaphragm. Inspect it carefully. Replace it if you find any tears or pin holes. A replacement is available through Harley Dealers for much less than the Kawasaki part.
• When reassembling the white plastic needle retainer, make certain it is not obstructing the slide lift hole. When seated correctly, there wil be very little vertical play in the needle.

Jetting Notes:

• The KLX Needle is much richer than the stock needle. If nothing else is changed, it requires a smaller main jet, and leaner mixture settings that a stock needle. It is also slightly richer than the Dyna Jet Kit.
• A good Baseline setting for a total stock KLR.
o #140 Main Jet
o #2 Clip Position
o 1 Ύ Turn Mixture Screw

• Removing the airbox snorkel may require a #142.5 main jet, and/or using the #3 clip position.
• A less restrictive exhaust system, and/or air box mods, may need a main jet in the #142.5 to 150 range. The stock main jet (#148 for 87 to 07, #145 for the 08) often works well. It may also need the needle circlip in the #3 or 4 position.
• Exclusive use at higher elevations, over 5000 foot, may need a main jet of 1 to 2 sizes smaller. A stock bike may need a #135 or 137.5. Removing the snorkel is highly recommended for all KLR’s, but more so when used at altitude.
• It is not required to re-jet for occasional use at altitude.
• Mixture screw settings will vary greatly from bike to bike. The effective range of the mixture screw is 1 to 3 turns. The greater the number turns, the richer the low speed mixture.
• The mixture screw and needle position overlap to a far greater extent than most people realize. (As does the pilot jet.) In general, the richer the needle is set, the leaner the mixture screw should be set.
• A small #4 washer can be used under the needle circlip for fine needle adjustments. A .020” thick washer will give you a “1/2 clip” richer change.

Opinions will vary but you might start with this, given that your exhaust is a bit freer flowing and the snorkel is out:

o #142.5 Main Jet
o #2 Clip Position
o 1 Ύ Turn Mixture Screw


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Last edited by Tom Schmitz; 02-19-2013 at 07:09 PM.
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post #3 of 4 Old 02-21-2013, 10:17 PM
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Join Date: May 2009
Location: Indiana/ Michigan line at the Lake
Posts: 1,586
Tom pretty much has it nailed.

This is my son, with whom I am well pleased." ----God
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post #4 of 4 Old 02-21-2013, 10:46 PM
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Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
Welcome from another Ontarian, I have used this setting and I live one hour north of Toronto for ellavation info.
I usually set the carb to....
two turns out on the pilot screw
145 main jet
Clip on the third slot with brass collar above the clip to hold the needle from floating.
slider drilled to 7/64th
4 3/4" holes drilled into top of air box
Snorkle out
UNI filter

I've had good results from this setting from all of the bikes I've done so far, but it is a good starting point to work from. Some may need tweeking depending upon each individual bike.

Hope this helps......

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