dynojet jet kit questions/concerns - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 21 Old 08-18-2016, 09:48 PM Thread Starter
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dynojet jet kit questions/concerns

I just installed a stage 1 DJ jet kit & fmf q4 slip-on on my 2016 klr. I got up this am & did a 90mi backroad loop & it seems to be running good but still has the 2500-3000rpm surging going on. cold start ups are waaaaay better, good idle, & pulls hard from idle, so im scratching my head. i'm suprised dj only has you swap main jets & not the pilot jet. also wondering if raising the needle one slot would help as well. Do any of you folks have any advice for this particular brand of jet kit.?
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post #2 of 21 Old 08-19-2016, 05:29 AM
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Got one for my CV40 on the Sporster and it was a headache from
the beginning and never got dialed in right. I messed with it on and off for a year
before going back to stock other than keeping the needle in. Ran great but had
flat spots in the rpm band, and gas mileage was in the toilet. (Yes, I know my carbs
pretty well.)

For a hotrod engine they are great. For a KLR, the general consensus is to install a
needle that fits the KLX, and stay stock on jetting or up one size on the main. Enrichening
the idle circuit, and the aggressive taper on the KLX needle are all we need. You didn't make
a bad choice. It's our engines. They just don't make enough power to justify the upgrade
when all we need is to sweeten up the lean factory setup which has to pass emissions testing.

Yes, go up one notch. Idle screw out 1 3/4 to 2 turns from gently seated.
I don't have any other useful advice. When I was on the HD tech forum most
of the guys didn't like the end result either.

I'd say keep fiddling with a few settings till it smooths out. You're pretty close it seems.
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post #3 of 21 Old 08-19-2016, 11:32 AM
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The bad news is that the Dynojet kit is way off. The good news is that all is not lost. Basically the needle is good but the jetting instructions are WAY too rich. (also keep in mind that different jets are numbered differently)

Use the DJ jet you already have but use the same jetting as the KLX kit from Eaglemike; 142 KH main, 2nd clip, no shims, 2 turns on the fuel screw. Pilot jet should be fine. My 2001 has this exact setup along with an FMF Q4 and a Gen2 header. Only other mods are the snorkle-ectomy (a must do) and the 4 - 1" holes in the airbox lid (recommended). I also run a Uni-filter.

My other KLR runs the KLX kit and both run identically.

Did you drill the slide? drilling it 1/8" can cause surging issues; the KLX kit recommends 7/64ths ....personally I didn't bother drilling my slides as it make zero difference to the jetting.


Dave
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post #4 of 21 Old 08-23-2016, 03:47 PM Thread Starter
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thank you guys for the replies/help, in the above post when you say keep the same dj jet, did you mean keep the dj needle, second clip, & use the factory kh jet? also i did drill the slide hole per dj's instuction which i cant remember off the top of my head the sizing.
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post #5 of 21 Old 08-23-2016, 05:10 PM
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Quote:
Originally Posted by klrcott View Post
thank you guys for the replies/help, in the above post when you say keep the same dj jet, did you mean keep the dj needle, second clip, & use the factory kh jet? also i did drill the slide hole per dj's instuction which i cant remember off the top of my head the sizing.

Yes, sorry....I misspoke....or mis-typed. Use your DJ needle but not the jets. Use a 142 KH main - stock is 148/145 depending on year but as soon as you change the needle, you can't compare them directly; i.e. a 142 main and a DJ or KLX needle is richer than a 148 main and the stock needle. that's a bit of an oversimplification because the needles "richness" changes with the angle of the taper, etc.....but you get the idea (I hope)

Cheers,
Dave
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post #6 of 21 Old 12-09-2016, 01:02 PM
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I am a bit confused. But maybe you can clear this up for me.

My bike is 2013 KLR650 and it has 145 main jet (KH), would that mean that in DJ standard I have 134?

So if I want to go to 148 KH main jet, then I have to use 136 DJ?

I find it very weird that there would be such a massive difference in numbers between KH and DJ.
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post #7 of 21 Old 12-09-2016, 04:53 PM
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Here for clarification: Use a 142KH OR 132DJ(same thing by the chart) with the DJ needle in the second clip. The pilot jet is fine as is. Set the idle mix screw 2 turns out.
It should run good there.
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post #8 of 21 Old 12-09-2016, 05:49 PM
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Quote:
Originally Posted by lagbc View Post
...I find it very weird that there would be such a massive difference in numbers between KH and DJ.
Keihin jet numbers are simply the diameter of the hole in the jet, times 100. Thus, a 142 jet has a hole in it that is 1.42mm in diameter. This is quite logical. So much so that even I can grasp the idea.

Dynojet numbers are somehow related to the amount of fuel that can flow through the jet given a certain head of pressure, at sea level and high tide, on a bright sunny day with no wind with the equipment held by two blonde German umbrella girls.

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Last edited by Tom Schmitz; 12-09-2016 at 05:56 PM.
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post #9 of 21 Old 12-09-2016, 06:11 PM
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Last edited by Damocles; 12-09-2016 at 06:16 PM.
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post #10 of 21 Old 12-09-2016, 07:38 PM
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Quote:
Originally Posted by justjeff View Post
Here for clarification: Use a 142KH OR 132DJ(same thing by the chart) with the DJ needle in the second clip. The pilot jet is fine as is. Set the idle mix screw 2 turns out.
It should run good there.
justjeff
Is this clarification based on Dyno results or just worked for you?

By the way, if you are answering to my posts, I was asking totally different question.
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