05 klr 250 carb swap - Kawasaki KLR 650 Forum
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post #1 of 19 Old 01-01-2014, 06:53 PM Thread Starter
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05 klr 250 carb swap

Hello everyone,

I am working on my 05 KLR 250. I bought it in pieces. I've gotten it all back together. I am having trouble starting this beast. It is getting a strong spark, and has 90psi compression. It is getting fuel. I've cleaned the air filter, but it will not stay running. It is very temperamental and i'm losing my patients. I am wondering if there is anything i am missing. I've rebuilt the whole engine(rings, timing chain, valves, magneto, guides, tensioner). My trouble i believe is in the carb. i've pulled it out a ton of times, and i checked the float height and cleaned the hell out of carb. Any ideas why i'm having trouble starting this bike. i've only gotten it running a handful of times but i cannot get it to stay running. And it only starts running after i kick it over 40-50 times. Any ideas?
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post #2 of 19 Old 01-01-2014, 09:45 PM
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If the slide diaphragm's properly sealed and totally intact; fuel screw out about 1.75 turns; and all orifices and galleries cleaned; can't imagine why the bike won't start and run.

A whiff of STARTING FLUID might give it some encouragement (have fire extinguisher handy).
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post #3 of 19 Old 01-02-2014, 12:48 PM Thread Starter
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The diaphragm is all good. Is there supposed to be a washer on the needle? What do you consider a turn on the fuel mixture screw 180 degrees or 360? I just ordered all new jets and internals for the carb. the bike has over 18k on it so it might just be time.
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post #4 of 19 Old 01-02-2014, 01:28 PM
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The diaphragm is all good. Is there supposed to be a washer on the needle? What do you consider a turn on the fuel mixture screw 180 degrees or 360? I just ordered all new jets and internals for the carb. the bike has over 18k on it so it might just be time.
1 turn would be a full 360 degrees. So about 1 and 3/4 full turns out.

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post #5 of 19 Old 01-02-2014, 01:31 PM Thread Starter
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Sounds good. Thats what I thought but i wasnt 100% sure. What about the washer. Is there supposed to be a washer on the needle that is in the top part of the carb(the long needle that is in the slide)?

Last edited by Mauryo; 01-02-2014 at 01:40 PM.
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post #6 of 19 Old 01-02-2014, 02:12 PM
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Sounds good. Thats what I thought but i wasnt 100% sure. What about the washer. Is there supposed to be a washer on the needle that is in the top part of the carb(the long needle that is in the slide)?
I'll let Damocles answer that, I have no idea as I've never had a KLR250 carb apart. I just knew what he meant by the turns . Cool bikes the 250's, scarcer than hens teeth in my neck of the woods.

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post #7 of 19 Old 01-02-2014, 03:13 PM Thread Starter
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I'll let Damocles answer that, I have no idea as I've never had a KLR250 carb apart. I just knew what he meant by the turns . Cool bikes the 250's, scarcer than hens teeth in my neck of the woods.
ok. sounds good thanks.

whats so scary about the klr 250?
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post #8 of 19 Old 01-02-2014, 03:44 PM
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ok. sounds good thanks.

whats so scary about the klr 250?
Lol, nothin scary, you just don't see many of them for sale here.

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post #9 of 19 Old 01-02-2014, 03:46 PM Thread Starter
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Lol, nothin scary, you just don't see many of them for sale here.
HAHAHA. i obviously don't know how to read. I now read back and saw u wrote scarcer not scarier. Are 650 and 250 parts compatible?
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post #10 of 19 Old 01-02-2014, 04:31 PM
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Sounds good. Thats what I thought but i wasnt 100% sure. What about the washer. Is there supposed to be a washer on the needle that is in the top part of the carb(the long needle that is in the slide)?
Stock, no washer. The "22-cent mod" involves one or two # 4 washers, but . . . not as popular a modification with KLR250s as with KLR650s.

(Full disclosure: 22-cent mod on my KLR650; stock carb on my KLR250, with fuel screw adjusted.)

Google, "Care and feeding of the CVK40" for a good primer on how your carburetor works; identical in many aspects (except for size) to your CVK34 on your KLR250.

Some parts are interchangeable between KLR650 and KLR250; check out the part numbers on fiches (available at Kawasaki and Bike Bandit websites, among others) before you assume interchangeability.

Back to basics; with spark, compression, and a combustible mixture, oughta run!

Good luck.
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