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Discussion Starter #1 (Edited)
So got a KLR 250 for the gal, she defiantly is going to need kouba links but I've got it down to something she can get up and kick start on.

Anyway, in pursuit of making it easier to start we've pulled the carb to check and clean as the last owner said he "rebuilt" and "rejected" the carb which from all my previous experience with kick start Thumpers means I will have to take it back to a baseline stock starting point to sort it all out.

So I have all relevant inter web data but wanted opinions from ya'll

It's all apart and soaking in Seafoam as I type.

Currently 125 and 35 (I think) Jett's and was 3 1/2 turns out with 22 cent mod, snorkel removed...

Only starts with no choke and rolling on the throttle while kicking...I am going to remove 22cnt washers and start with maybe 2 turns on the mix screw and see if I can get the choke back in the game.

Me thinks overly rich hence open butterfly (throttle) on start added more air to the mix..idled high and hung then drops which would make me think too lean but could also be cables and choke setting...not sure till we put it back in.

I would like to dial it in to make it easy for her even though I personally think the bruises on her leg from kickstarting are kinda of sexy, like having grease smudges on her face. :):)

Any advise would be appreciated...I've had old bore bores and know my way around but never owned a KLR250

Experiences and opinions welcome!!!!
 

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Model year would be helpful; specifications differ somewhat between them.

Picking a time stratum as a starting point, the US and California main jet size stock is 118 (previously, 120 for US); pilot screw out 2 turns (kinda ambiguous in Kawasaki KLR250 supplement service manual, could be 1-3/4, depending upon how countries are listed).

I concur, sounds like the carb is jetted 'way too rich.

While I have the 22-cent mod on my KLR650, IMHO, the KLR250 don't need no stinkin' 22-cent mod; YMMV.

The "choke" (starting enricher) plays its role with my '03 KLR250. After sitting a long time with no engine activity, I find turning off the fuel petcock and applying the choke helps on initial start-ups.

And, I confess; sometimes, starting fluid is my friend! :)

Be sure the diaphragm fabric is intact, and its peripheral edge fully seated in its groove in the carb body on reassembly. Nothing against Sea Foam, but . . . I'd favor a harsher chemical for a carb soak.

YMMV, but I find my KLR250 screams and runs like the wind with stock carburetor, intake and exhaust.
 

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Discussion Starter #3
Hey thanks

Spaced out about this post...

Removed 22cents washers, everything in tact. Rebuilt, starts better. Choke does its job. When warm one kick no throttle needed.

Cold. 5 prime kicks, choke on, 2nd real kick starts up.

Still hangs up around 3000rpm sometimes before idle drops to 1500.

New throttle cables as well, old ones had cracked housings.

Getting better though.
We at sealevel so maybe the 125 jet is ok, might try smaller though. Still takes a little throttle at start up...let's more air in I spose, rather than more fuel initially.

Jus going through it slowly, one thing at time..better everyday.
I think it had a hard life.
5 owners in 7000mi, probably all newbie 20yo males trying to get more performance out of it. If we hadn't bought it, it would have been trash in 5yrs.

Being a KLR though, it's solid and is almost back to showroom mechanically, cosmetically might need some plastics.

2003 btw

Thanks again.
 

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So's mine!

And, it's stock, like STOCK, engine-wise, except--fuel screw (idle mixture screw) adjusted. Pulls smoothly, up through 5 figures rpm; "clocked" by a BMW at 80 mph + ("professional rider, closed course, do not try this at home, etc."). WHAT? ME worry? :)
 

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Discussion Starter #5
Yea might try stock jets, can't hurt, everything else is stock...and...gas mileage will improve.
 
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