tag:blogger.com,1999:blog-1470977745393566479.post5369190889972233842..comments2023-08-08T04:07:21.151-04:00Comments on Kawasaki KLR250: Kawasaki KLR 250 Carb Cleaning InformationUnknownnoreply@blogger.comBlogger55125tag:blogger.com,1999:blog-1470977745393566479.post-4505663622265090512017-09-19T10:18:34.007-04:002017-09-19T10:18:34.007-04:00Great article. I have a 1996 KLR250. Fuel was sh...Great article. I have a 1996 KLR250. Fuel was shut off but the varnish in carb. finally makes keeping the motor idling without some choke impossible.<br />This straight forward article will really be of help!Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-46023548238444282342016-10-03T01:47:17.720-04:002016-10-03T01:47:17.720-04:00Thank you. Had the same question and couldn't ...Thank you. Had the same question and couldn't find anything anywhere.Aaron Cheatwoodhttps://www.blogger.com/profile/11216660605135638349noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-24198549408678868972016-07-21T07:02:17.950-04:002016-07-21T07:02:17.950-04:00Hope someone can help, I have a 92 KLR250, which h...Hope someone can help, I have a 92 KLR250, which haven't had very long, and had been running great, but come to start it after a journey out and it don't want to know. Found I have a problem with a loose pipe which has petrol dripping out of it. Being a girlie - bit thick here with engines I'm afraid, can't see an obvious place for it to go back. So simple terms and preferably a clear picture or two of the carburettor and pipes, so get an idea of what I should be looking at, would be very much appreciated, can anyone help please?Tracynoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-57414520807710503392016-05-31T15:41:44.922-04:002016-05-31T15:41:44.922-04:00Thought I'd throw this in just in case someone...Thought I'd throw this in just in case someone is in the same boat that I was. If you're having trouble with a hanging erratic idle, make sure you have that spigot on the top of the carb plugged up. I think it's specific to the California model, and the P/O had removed the fuel recycling system leaving that spigot unplugged. I was going crazy for months, and felt pretty silly once I realized that was my quite simple issue. Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-16265022555175066212016-04-12T22:20:51.503-04:002016-04-12T22:20:51.503-04:00Have you tried adjusting your valves yet? Seems t...Have you tried adjusting your valves yet? Seems that you should around every 3k miles (if memory serves me right)..looks like you're due. Wouldn't hurt to check / have checked...much more expensive result if they're in need of adjusted and get neglected.<br />Otherwise, perhaps you overlooked some foreign material upon Carb assembly.<br /><br />Hope this helps ya.Anonymoushttps://www.blogger.com/profile/00341996916471721282noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-65936567581013481472016-04-12T22:17:34.126-04:002016-04-12T22:17:34.126-04:00I'm the same guy from 4/11/16 post directly ab...I'm the same guy from 4/11/16 post directly above.<br /><br />I've been "cheating" by using starting fluid (I'm embarrassed to admit that yes...I drilled a small hole in the air cleaner box, installed a small "door" to cover it after shooting ether into the box). After all, I'm in my 40's, have flamingo legs and it's killer to kick this animal 50+ times before bringing her to life.<br /><br />Attempting to take one last stab at her before just buying another carb, I've finally identified the trouble.<br />Seems that the starter jet is / has been clogged.<br />Looks like the P.O. found out too as there are witness marks on the brass flange of the starter jet (assuming left by vice grips or pliers) and also it appears that he started to drill it out as there is material lapped over the hole...and she's plumb plugged beyond that...<br />I have:<br />Adjusted valves<br />replaced Pilot and main jets, idler screw, etc, float plunger<br />Installed a brand new plunger assembly ("choke")<br />Cleaned carb 4x now<br />Opened up the air box to ensure good air flow<br />replaced air filter<br /><br />I'm CERTAIN this is my problem. Fuel can't make it's way through the winding passages up to the choke circuit for the "next" start.<br /><br />Wondering if anyone has experienced similar trouble and what the thoughts might be if I were to just drill out the STARTER jet.<br /><br />Any takers? <br />Any help / advice would be GREATLY appreciated!Anonymoushttps://www.blogger.com/profile/00341996916471721282noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-55334782874813962262016-04-11T21:48:09.926-04:002016-04-11T21:48:09.926-04:00Anyone have any idea why I would find a washer bet...Anyone have any idea why I would find a washer between the Needle Jet holder (13091 above) and Jet Needle (16017 above)?<br />I've been having trouble with cold starts since I bought this bike 3 years ago (95 KLR 250), have been thru the carb numerous times, adjusted valves, replaced choke plunger, etc, etc) and haven't been able to solve the issue.<br />Tonight, I decided to tear into her again only to find pilot jet clogged...I'm SURE I cleaned that out last time but...anyway, I noticed that there is an extra "washer" between the two items mentioned above. Seems that it shouldn't be there as I compare to the exploded view above.<br /><br />Any takers? Maybe the well is stripped out and P.O. put it there to compensate? <br />Perhaps some weird mod that is designed to "help" in some way or another?<br />Any takers? Thanks, JasonAnonymoushttps://www.blogger.com/profile/00341996916471721282noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-78511606046523068742016-04-09T22:33:07.180-04:002016-04-09T22:33:07.180-04:00It's possible that Mike is no longer monitorin...It's possible that Mike is no longer monitoring this thread, but just in case...<br />I followed - and greatly appreciated - the step-by-step process to clean the carb. I admit that I hoped that was the problem with the bike. 2003 model KLR 250. I've had it for 2500 miles. It ran perfect when I got it. I was riding it less after I added another bike to the family, but still at least monthly. Recently is started sputtering on initial take-off after a warm up. Rolling on the throttle got little reaction, and then all of a sudden it would kick in. Weeee. It would also occasionally hiccup en route. So I figured that even if it didn't fix it, cleaning the carburetor couldn't hurt.<br />After putting it all back together, it starts great, but if I even try to roll on the throttle, it stalls out. Worse now, since I can't ride at all, then before. :( . Thoughts? Help? Georgianna Woodhttps://www.blogger.com/profile/05203530528473629208noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-39545510282557139892015-11-14T17:38:22.831-05:002015-11-14T17:38:22.831-05:00Great info Mike. I have a question about a CVK car...Great info Mike. I have a question about a CVK carb on my KLR 650. How does the starting circuit work? I know the fuel is picked up in the bowl then it goes to the choke plunger but where does the fuel go from there? In other words how does it get to the carb throat after it comes out of the choke plunger? Thanks Mike. <br /> <br /> <br />kAnonymoushttps://www.blogger.com/profile/13966387007187918092noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-21827287484966287362015-10-20T12:44:39.790-04:002015-10-20T12:44:39.790-04:00Great info! There is also a great four-part YouTu...Great info! There is also a great four-part YouTube video that shows the disassembly/reassembly of a KLR650 carburetor, which is almost identical in every way; here is part one of the video: https://www.youtube.com/watch?v=YUHbq07qcCk&app=desktopAnonymoushttps://www.blogger.com/profile/05332759408308302939noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-5141232306795356362015-08-23T20:03:47.005-04:002015-08-23T20:03:47.005-04:00I have a pretty similar problem. I think that the ...I have a pretty similar problem. I think that the throttle position determines which jet or combination of jets is supplying fuel at any given time. If the problem is like mine, then at a medium throttle position, the bike goes steadily, but on opening the throttle, there's a noticable delay/diminishing revs, unless you open the throttle quite slowly, when the revs pick up ok. If this is the case, then it's likely to be main/needle jet wear, which can cause 'rich cut', effectively flooding the bike as surely as putting the choke on. Anyway, replacement of these shouldn't be too expensive or difficult and can only improve performance of any bike in any state.Cheesebuttynoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-57582140899653793742015-08-20T19:07:21.228-04:002015-08-20T19:07:21.228-04:00on my 94 plate their are coolant pipes fit on to b...on my 94 plate their are coolant pipes fit on to bottom of carb at each side next to float bowl one goes on left side one right side you cant go wrong its the omly pipes fit down at float bowl<br />Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-66984734879285865782015-07-25T22:35:06.668-04:002015-07-25T22:35:06.668-04:00just bought a klr 250 runs but as soon as I give i...just bought a klr 250 runs but as soon as I give it some throttle she looses rpms and will die if I don't throttle down I have to slowly power up and it will only get to about 4000 rpm and then falls flat . I have never worked with these damn diaphragm carbs before. any ideas?<br />Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-81293997657041655752015-07-23T18:56:15.328-04:002015-07-23T18:56:15.328-04:00Knowing my 2005 KLR250 would be sitting for about ...Knowing my 2005 KLR250 would be sitting for about six months, I ran the carb dry with the fuel valve in the OFF position, then drained the gas tank. Fast forward to today. I put about a gallon of fresh gas in the tank, and the bike started right up! Problem though! Even with the fuel valve in the OFF position, fuel ran out the over flow hose until the tank was empty. Is it possible the fuel valve is defective AND the needle and seat are stuck at the same time…all while the bike runs great? Help!Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-79933399374909634402015-07-21T20:09:13.239-04:002015-07-21T20:09:13.239-04:00I had an identical issue. Couldn't get anythi...I had an identical issue. Couldn't get anything through the pilot jet and couldn't see any light through it. Finally ordered a new pilot jet, blew out the carb and thoroughly cleaned the float bowl (especially the lowest point near the drain where dirt can get trapped), put it all back together and all's well. Looking through the new pilot jet it appears there are three tiny holes inside the orifice so there's no way to get anything through there larger than possibly a single strand of small wire. I had tried that with the old jet but the wire just kept bending. Good luck.Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-86323428085697524322015-06-13T11:30:04.042-04:002015-06-13T11:30:04.042-04:00Thanks for your help.
Does anyone know if the pil...Thanks for your help. <br />Does anyone know if the pilot jet screw should be clear all the way from the screw driver end to the tube? I can't get any pin through it. My 2003 klr 250 carb is cleaned, but the engine only starts with starting fluid with open throttle and will stay running that way. Only 3200 miles on this bike. The jet looks like it has a drilled spot in the middle of the screwdriver slot. Thanks for all help. Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-34329570552630829882014-09-08T01:04:38.745-04:002014-09-08T01:04:38.745-04:00Hey guys I'm so lost! I have an 87 klr250 and ...Hey guys I'm so lost! I have an 87 klr250 and I have the carb off and disassembled due to the fact that it has been sitting for 5 years. We got her to start with starting fluid but dies as soon as thats burned up. Simple, not getting fuel. I have cleaned everything but now my problem is the fuel inlet (the black nipple on the bottom) I think Is clogged? I can't blow through it or suck. Somehow for some reason nothingg is getting through there.... any ideas? How do I clean that? I'm not sure how to remove the black nipple without breaking it and I'm not sure on the float needle removal... any ideas would be so greatly appreciatedAnonymousnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-61170112461603449522014-08-22T19:46:36.413-04:002014-08-22T19:46:36.413-04:00I guess it's possible if it's clogged with...I guess it's possible if it's clogged with rust. Check inside your fuel tank when its empty and see if there is any run. If so then go with a brass style filter between the tank and the carb. My bike had tons of rust in the tank and would clog the carb time after time. The fuel filter fixed it.Mikehttps://www.blogger.com/profile/01016117565107892052noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-22007654082613650522014-08-22T12:54:37.208-04:002014-08-22T12:54:37.208-04:00Hi Mike - back again with another question. After...Hi Mike - back again with another question. After completing the carb overhaul a 3 months ago the bike ran great. I put it away, then was out of town for awhile. The other day I tried to start it again, and it wouldn't start. No fire, nothing. After wearing my leg out on the kick starter, I finally relented to having to take the carb off again. Doing so, I discovered the pilot jet is clogged again. I stuck a wire down the middle of it but the wire bent. I used a paper clip, and it bent too. I tried the end of a safety pin - same result. It's as though it was made this way, but I know it wasn't since I cleared the same jet 3 months ago. It seems like everything I put in that hole hits metal (or something equally as hard) halfway down. To clariify, this is part # 92064 in your parts diagram. I'm about to order a new pilot jet, but wanted to see if you had ever heard of a jet clogging this badly before. The gas has Stabil in it and I did install a fuel filter back in May, but possibly something was in the system already. Thanks for any advice.Leo Taylorhttps://www.blogger.com/profile/07616011303790519732noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-965672178031749492014-05-28T19:23:53.802-04:002014-05-28T19:23:53.802-04:00I have this same bike. I have tried over and over ...I have this same bike. I have tried over and over to clean the carburetor. Nothing new been doing these cleanings on outboards all my life, but this one has stumped me. I dont have Japanese size fingers so makes for a very frustrating day in the hot sun taking the carburetor in and out and eventually I abandoned the project. The bike has sat for nearly a year and i was looking yesterday online for anyone else with this problem and came across your post. Went right down your list. Just put it all back together and it fired right up and runs like a top.<br />Appreciate the tip..Anonymoushttps://www.blogger.com/profile/11294926424898375164noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-90566032987939369122014-05-12T21:56:58.270-04:002014-05-12T21:56:58.270-04:00The old KLR is finally running again and sounding ...The old KLR is finally running again and sounding great. Didn't have time to take it for a test ride but it's running good in the shop. Had to open up the carb again and check the pilot circuit. Removed the pilot jet and discovered it was clogged, so cleaned it out with a very fine piece of wire. All the carb cleaner and air pressure hadn't touched it. My carb cleaner was quite old so maybe that's why. Fired right up after that. With it running I was able to adjust the pilot mixture, then set the idle. Running like a sewing machine now. Last thing to do is add the Stead Engineering alloy choke nut, which should be arriving soon. Thanks so much for your informative blog Mike, it was a big help to me.Leo Taylorhttps://www.blogger.com/profile/07616011303790519732noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-76266802930232542852014-05-10T12:04:33.237-04:002014-05-10T12:04:33.237-04:00Well I replaced the needle but the bike wouldn'...Well I replaced the needle but the bike wouldn't start. Turned out the seat was completely clogged (this was after a good soaking in carb cleaner and spraying out with canned carb cleaner). I was able to clear it with a very small wire and more carb cleaner. Put it all back together and then the needle wouldn't seal in the seat. Gas flowed freely out of the overflow despite having verified the correct float level earlier. Took it apart again and took a good look at the seat, which appeared uneven and possibly corroded. Tried to get it out but couldn't budge it. Ended up trying to clean it up with a very small pointed stone on the end of a dremel, then recalibrated the float level. Needle and seat are now working properly. New problem now though. Bike fires two or three times but won't fully start. Going at the idle adjustment next. Leo Taylorhttps://www.blogger.com/profile/07616011303790519732noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-3166180658249744222014-04-25T20:44:27.199-04:002014-04-25T20:44:27.199-04:00Yep, improper valve clearances will definitely mak...Yep, improper valve clearances will definitely make the bike hard to start. The pilot jet controls the the fuel flow at idle and just off idle. And yes, the starting circuits are just the passages in the carb that aid in startup and idle. Mikehttps://www.blogger.com/profile/01016117565107892052noreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-14522624417930216512014-04-25T20:41:32.770-04:002014-04-25T20:41:32.770-04:00Thanks for the reply- I will check out the pilot j...Thanks for the reply- I will check out the pilot jet. What is the purpose of the pilot jet? Also, what is the "starting circuit" you referred to- is that all of the passages that lead to the choke that aid in starting? <br />As far as the valves, they were supposedly set by a mechanic recently but I'll try to check them as well. So if I understand correctly, misadjusted valves could affect starting but maybe not affect normal operation when it's warmed up? <br />And that's a good idea to look at the seal between engine and carb- definite possibility of extra air getting in there.MCnoreply@blogger.comtag:blogger.com,1999:blog-1470977745393566479.post-74477134646640443202014-04-25T17:12:43.916-04:002014-04-25T17:12:43.916-04:00That's a tough one because techincally it coul...That's a tough one because techincally it could be a number of things causing that and possibly a combination of things. If you haven't set the valves in a while that is definitely something I'd start with, along with giving the carb a through cleaning. Since you have to use starting fluid to get it running that means there is a lack of fuel or too much air entering the engine. Possibly a leak between the carb and engine? Or a clogged pilot jet or starting circuit in the carb.Mikehttps://www.blogger.com/profile/01016117565107892052noreply@blogger.com