Gears not holding on ‘08 KLR - Kawasaki KLR 650 Forum
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post #1 of 3 Old 01-01-2019, 12:22 PM Thread Starter
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Gears not holding on ‘08 KLR

Just rebuilt carb. Had to adjust fuel mixture valve to tune engine to hold rpms between 2k - 3k. Under load, the bike sputters in each gear and shuts down between second and third. Suggestions welcome!
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post #2 of 3 Old 01-01-2019, 10:36 PM
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The most common issue with folks rebuilding the CVK is that the either pinch the edge of the diaphragm or they tear the diaphragm. In either case, the slide cannot rise and the engine lacks power.

There are other possibilities, but the diaphragm is the most common.

BTW, your bike should idle at 1200-1500 rpm.

Tom [email protected]

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post #3 of 3 Old 01-07-2019, 10:48 AM
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Originally Posted by Bubbaloo View Post
Just rebuilt carb. Had to adjust fuel mixture valve to tune engine to hold rpms between 2k - 3k. Under load, the bike sputters in each gear and shuts down between second and third. Suggestions welcome!
I'll suggest that your carburetor is not thoroughly cleaned.
Specifically the 3 low speed pilot outlet holes just under the bottom lip of the throttle plate. They get their fuel from the pilot jet as does the adjustable pilot mixture screw.
But most 1st time mechanics totally miss seeing them!
They are the primary fuel control between actual idle & about 1/4 throttle. Right where you are having problems, correct?

With the pilot jet removed, I use a tiny wire bent 90 degrees to poke down thru them and back flush with aerosol carb cleaner & compressed air.
Then temporarily close the mixture screw.
Then with the aerosol straw positioned up in the pilot jet pocket spray fluid up thru to confirm that ALL 3 flow a full steam.
Re-set pilot mixture screw to 2 turns open & spray again. You will notice that most of it wants to flow out of the adjustable hole.

pdwestman
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