Carb issue after cleaning/22 mod - Kawasaki KLR 650 Forum
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post #1 of 26 Old 09-15-2015, 10:14 PM Thread Starter
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Carb issue after cleaning/22 mod

So I wanted to clean my carb on a new to me 08 klr650. I work as and own an automotive mechanic shop so I do know a little bit about carbs and stuff. Even though I was born after fuel injected was on all cars lol I have rebuilt/ cleaned motorcycle carbs before. It started out before carb removal and cleaning the bike had a slight hesitation when throttle was opened fast. After removing and cleaning jets and performing 22 cent mod. (1 washer under needle ) and drilling slide 7/64ths the bike now has almost no acceleration past 2500 unless it's very slowly revved. And the throttle is twisted fast engine will die. Any suggestions. Bike was very rideable before but not now haha. Left the shop after spending a couple hours pulling my hair out haha any advice is appreciated. Thanks
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post #2 of 26 Old 09-15-2015, 11:47 PM
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Check the diaphragm for improper seating and/or a tear or hole.

Tom

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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post #3 of 26 Old 09-16-2015, 08:02 AM Thread Starter
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Thanks Tom. I have checked the diaghphram multiple times and no tears or holes. I was able to slide the rear subframe and air box back and the seems to work properly. If I slowly roll the throttle the slide goes up and stays up. But if I give it lots of throttle it bounces around with the engine rpm. Which is what I expect. After doing a bunch of research last night I'm thinking I lost the silver jet needle in the process of blowing out the carb. I will know this morning when I go back to the shop this morning. Thanks again for all the help. I will for sure be keeping the forum updated. And I will check the diaghphram again just cuz haha
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post #4 of 26 Old 09-16-2015, 08:45 AM
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Ah! The dreaded needle jet!

Yeah, that'll screw things up if it's gone missing.

Tom

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #5 of 26 Old 09-16-2015, 10:51 AM Thread Starter
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So I got to the shop this morning and pulled the carb back off and to my disappointment the needle jet is still in its proper location. Back to the drawing board lol! Or banging my head on the wall. The only thing I haven't put back to before the mod is the slide hole but I just can't see this causing my problem. Used a 7/64th bit
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post #6 of 26 Old 09-16-2015, 11:36 AM
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I hope I'm not getting too remedial on ya, but here are some things to check.

Put these in the order that works best for you:

If you haven't seen it, review the attached document.

Take a look at these videos:

http://www.youtube.com/playlist?list...JDN-M-H_ha-mIF

and look for things in your carb that might be out of place.

The slide rises under engine vacuum, so look especially for things that are preventing vacuum from getting to the top of carb, the upper diaphragm chamber, and for things that would make the vacuum ineffective (again, some sort of defect in the diaphragm itself ). It could be something as obscure as one of the fingers on the white dealy-bop-thingy covering the hole. Drilling the hole to 7/64" cannot be a problem, unless the wrong hole was drilled.

Make sure that you have no intake leaks on the engine side of the carb, such as a loose or mis-installed intake boot or a cut, crack, or hole in the boot.

Make sure that the bowl vent is clear, even going so far as to remove the vent elbow and make sure it is clear.

Do a fuel level check on the bowl by attaching a bit of 1/8" clear hose to the nipple on the bottom. Apply vacuum to the petcock to make sure that it is open. Bring the hose up along side the carb and open the bowl drain. The fuel should rise up to about the gasket level on the bowl.

Do a fuel flow check on the petcock by disconnecting it from the carb, applying vacuum to the petcock to insure the petcock is open, then flip the lever to "On" and then "Reserve". In both positions you should get a strong and steady stream of fuel.

If the vent is clear, the fuel level is right, the petcock flows right, the diaphragm and vacuum passages are good, and there are no intake leaks, you will probably need to disassemble the carb and give all (and only) the metal bits a 24 hour soak in Pine-Sol, then clean every passage and orifice really well.

That's about all I can think of right off the top of my head. If you can report any other symptoms that might provide clues, that might be helpful in diagnosis.

Tom
Attached Files
File Type: pdf Care & Feeding Of The Keihin Carb.pdf (1.34 MB, 7 views)

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #7 of 26 Old 09-16-2015, 01:55 PM Thread Starter
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Thanks Tom I watched the videos and assembled carb accordingly. no change. checked for vacume leaks no problems found, I did however mess with the slide using my finger through the airbox side of the carb. if I lift up on the slide while twisting the throttle no change it still bogs. however if I put a slight bit of pressure down on the slide to keep it from going up so fast the bike WILL REV!!! so I think im on to something here. the slide is going up to fast or to far. bogging down the motor. how do I slow it down or what does this? do you know the stock size of the hole in the slide? Thanks again Tom
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post #8 of 26 Old 09-16-2015, 02:48 PM
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What's rattling around in my head is:

Missing spring
Broken spring
Missing main jet
Huge main jet
A KLX needle that is way out of whack on the clip
A KLX needle with a missing collar (although they usually still rev OK with a missing collar)
A stock needle that is somehow installed way too high.

...because it sounds like it is very rich. The slide usually doesn't present any problems, and the 7/64" hole simply improves the response a bit. It is barely larger in diameter than the stock hole. These things I mention are rather extreme and unlikely since you gone over it twice. If everything that is supposed to be there is there, I can't think of what would cause the slide to go up farther than it should.

I don't know what the stock hole size is, but I'd guess at 3/32" or 5/64" or some metric equivalent in that range.

If you accidentally, um, asked your shop helper to drill the hole and he mistook a 7/32" bit for a 7/64" bit there might be a problem, but I'm not sure what it would be...

Tom

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #9 of 26 Old 09-16-2015, 03:05 PM Thread Starter
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Hey Tom Thanks for the reply spring is there and does not appear to be cut or broken cuz the ends of the spring touch the next coil if that make sense. needle is stock I believe. no clip or groves on it for a clip. have tried one #4 washer under the needle measuring .035 and it makes no diff with or without it. main jet is a 145 which I believe is stock? collar is in place. and no I drilled the hole myself lol I am my only employee for now.
before I removed the carb it ran almost great except for a slight hesitation at first when it was accelerated hard. but now it wont rev so it has to be something I did. either in the carb clean, or the hole I drilled. and I keep looking at the new package and it says 7/64 on it lol thanks tom just got some epoxy and think im gonna try going with a smaller hole. cant think of anything else
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post #10 of 26 Old 09-16-2015, 04:19 PM Thread Starter
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Hey Tom Just wanted to give an update. I epoxyd the hole up and drilled it with a 5/64th bit and the bike revs up great so for some reason the 7/64 hole was to big on my bike. cant think of why but it will rev now lol and seems to rev faster than I first started so im happy. Thanks for all your help. I have another size up bit the 3/32 but im not sure if I should use that lol looking forward to more of these mods im seeing on this forum. THANKS again tom gotta put it all back together and take it for a spin
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