KL600B Jetting - Kawasaki KLR 650 Forum
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post #1 of 8 Old 04-05-2019, 10:40 AM Thread Starter
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KL600B Jetting

Hello Guys,

After my successfull engine/Top end rebuild (another thread) I am finally able to go through registration here in Switzerland.
For my Emissions form i Need a specific Jet/Needle combination…
I have a 1986 (could also be 1985, I only have the year of first registration as a date) KL600B, currently it has a 138 Main jet, N24B Needle, 40 Idle Jet installed.

The guys at the registration Department now told me i would Need a 150 Main Jet, N24C needle and a 40 idle Jet.
In all the documentation i found there is either a 135 or a 138 Main Jet and 150 seems way to large for me (for a stock bike)
Also the 138 Main Jet was used with N24B and N24C Needles, what is the difference?

Thanks for your help!
-phstka

Last edited by phstka; 04-05-2019 at 11:15 AM.
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post #2 of 8 Old 04-05-2019, 05:37 PM
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Wow… How do they check it?

2017 KLR in black
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post #3 of 8 Old 04-05-2019, 07:21 PM
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The USA model KL600-B1 & B2 models used 135 main jet, N24F needle & 40 pilot jet.

My OEM service manual Supplement #99924-1063-51 shows other countries to use 135 main jet, N24B needle, 40 pilot jet.

For 4000 feet and above for emission purposes it is suggested to change Down to 132 main jet & 38 pilot jet.

I do Not know which alpha is leaner or richer on the Keihin needles or where one might acquire one. N24F available in USA. N24B maybe available from Canada. N24C ???

I agree with a #150 main jet being WAY TOO Rich.

Does the registration Department TEST the exhaust after you swear you installed their required parts?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 83,000+ miles & counting
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post #4 of 8 Old 04-06-2019, 07:42 AM Thread Starter
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Thanks for the replies!

Unfortunately I got the bike with a french registration, because of that and it beeing over 30 Years old i have to get a signed form from Kawasaki Switzerland that prooves i have the right parts installed (that form alone costs 800 swiss francs by the way )

All of that just because switzerland isnt in the european union and therefore has its own noise and emissions rules for These old bikes (newer ones have a COC that prooves it is conforming to the new shared rules between switzerland and the EU)

long story short i have to bring my bike to a Kawasaki dealer and they check if the right parts are installed, after that they fill out the form and i can get it registered.
Maybe i can talk them into filling it out anyway but i wanted to be sure they at least have the right jet sizes (which they apparently dont when they suggest a 150 Main Jet )

I found the following repair Manual which should be right for me in the first collumn:


anyone else out there that knows whats the difference between the N24B and N24C needle?
Also were there different "throttle slides"? (I dont know the correct term in english but i mean the vacuum sliding Thing )

-phstka

Last edited by phstka; 04-06-2019 at 07:46 AM.
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post #5 of 8 Old 04-06-2019, 09:28 AM
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phstka

I find it amazing that you're being put through such an ordeal just to get a motorcycle registered.

Ironically I just bought a 600B1 earlier this week. In my case though, I picked up the registration and plate at our tax collector/DMV on my way home. Maybe we're the bad ones here; dunno.

Also...fwiw...the owner had the Service Manual and the Supplement that he included in the deal. The needle jet marks, as they're called in your screen shot, is just the Keihin needle part number. Needles come in different sizes...length, width and tapers. You should be able to find info and tables online to decode the part numbers N24B and N24C to see what the differences are, but I don't see how that's going to help with that red tape.

The N24C that your gov wants you to use is at least available on US-based Kawi OEM Parts sites, but you have to go to the US 600A1 model in the part fisches. As mentioned above, they changed the US spec from N24C to 24F for B1-B5 model years. I'm not sure if you're aware but there's a Service Manual Supplement (as referred to in a previous post) to the above screen shot for B1-B5 models that has the changes. I also see that the 150 Main Jet is also available for the CVK40 from other online sources.

Good luck!
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post #6 of 8 Old 04-16-2019, 01:57 AM Thread Starter
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Originally Posted by Bill10 View Post
phstka

I find it amazing that you're being put through such an ordeal just to get a motorcycle registered.

Ironically I just bought a 600B1 earlier this week. In my case though, I picked up the registration and plate at our tax collector/DMV on my way home. Maybe we're the bad ones here; dunno.

Also...fwiw...the owner had the Service Manual and the Supplement that he included in the deal. The needle jet marks, as they're called in your screen shot, is just the Keihin needle part number. Needles come in different sizes...length, width and tapers. You should be able to find info and tables online to decode the part numbers N24B and N24C to see what the differences are, but I don't see how that's going to help with that red tape.

The N24C that your gov wants you to use is at least available on US-based Kawi OEM Parts sites, but you have to go to the US 600A1 model in the part fisches. As mentioned above, they changed the US spec from N24C to 24F for B1-B5 model years. I'm not sure if you're aware but there's a Service Manual Supplement (as referred to in a previous post) to the above screen shot for B1-B5 models that has the changes. I also see that the 150 Main Jet is also available for the CVK40 from other online sources.

Good luck!
It really is amazing what i have to go through to just Register a motorcycle that even was sold here in switzerland!

Could you (or anyone else) provide me with the full KL600B Supplement? I am asking all these stupid questions about the needle and jet sizes because i get the impression someone at the registration office falsely looked at a KLR 650 (I think the KLR650 had a 150 main jet?) or something else to get me the numbers to the parts i have to install.

The N24C Needle is very hard to get here (because it was never used in europe it seems) and the 150 Main jet is probably way to rich what would probably screw up my emissions test, So i Need the official Kawasaki paperwork to just prove they have the wrong data.

After digging a Little deeper everyone said that the swiss version of the 600B had exactly the same jetting as the european /german version
(the german repair Manual Supplement sais the following i think, but i could not get it from anywhere -not even an official dealer- and buying it in the us is a hassle and takes a long time)

(Switzerland is CH and Germany DE)


I much appreciate you all helping me through this hassle!
Greetings
-phstka

Last edited by phstka; 04-16-2019 at 02:12 AM.
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post #7 of 8 Old 04-16-2019, 04:43 AM
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I wonder if your EMISSIONS CHECKER man might not be operating over a KLR650 specification list, in contrast to one for the KLR600?

Absurd regulation; even if OFFICIALDOM physically checked component conformity, or even performed an actual emissions test . . . nothing I'm aware of prevents one from taking his bike to his garage and installing the parts of his choice, after inspection.

Hard (for me) to imagine, but . . . scads of politicians in the USA want even MORE regulations than now exist, ESPECIALLY in the, "ENVIRONMENTAL" realm. We shall learn how GREEN they will go, in future elections!


“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #8 of 8 Old 04-16-2019, 06:30 AM
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My Service Manual and Supplement are hard copies, although I found an electronic copy of the Manual for the 600A1 doing a search; not the supplement. Maybe you'll have better luck than me, however, I see that Supplements are for sale on places like eBay. The Part Number is 99924-1063-52.

The initial Service Manual screenshot that you provided was from page 2-3 of the A1 Service Manual. By reference to the abbreviations list on page 1-7 of that manual, U=US Model, G=West German Model, W=Swiss Model…so I think the new information that you have is also pre-Supplement; i.e. it’s for the 84A1.

Here is a photo of the page from the Supplement that shows the changes. There are only two pages in the Supplement Fuel System Chapter. One is the index to the chapter and the other is the page I’ve linked below.

https://photos.app.goo.gl/gi7q3t1DjiXGSRT46

Glad to make scans or photos of whatever you need from the Supplement until you can get your hands on a full copy.
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