Carburetor Rebuild
05-18-2009, 10:39 AM
#1
Honda-Tech Member
Thread Starter
Carburetor Rebuild
With the forks out and draining, I pulled the KLR's carburetor to clean it. I had a dead spot from about 1/4 throttle to 3/4 throttle then it pulled like a beast. Since this bike is pretty old and all the other maintenance has been lax, I figured a good scrub can't hurt.
To start, put the petcock valve to OFF and then remove the hoses going to and from the carburetor and drain the float bowl. There's a little valve on the bottom of the carb just for that purpose. With the gas tank removed, the KLR looks like any other bike:
Some ghetto wiring that I'll be replacing:
Removing the carburetor on a single is an easy job. The only trick is disconnecting the choke circuit. To do this, I removed the chock lever from the handlebar to give the cable housing some slack. It then unbolts off the carb body (its the brass thing under the cylinder head). The housing is PLASTIC!!! and easily damaged. Go Green! :uhg:
I pulled off the throttle cables and loosened the manifold and airbox clamps. A little wiggling and the carburetor slid right out.
This is by far the dirtiest carburetor I've ever rebuilt. It took a full can of carb cleaner to get this thing clean after taking it all apart! The jets and needle were placed in a parts dip for day and then blasted with more carb cleaner and then compressed air. All the other ports were given the same treatment.
More pictures to follow:
One of the things I did was shim the needle using a pair of #4 brass washers. I'm hoping that this helps my mid-throttle dead spot. I was happy to find that the jets were both OEM spec and that the fuel mixture screw was already adjusted out.
I replaced all of the phillips head screws with 4mm hex bolts. Two of the screws on the float bowl were mangled and had to be removed with vice grips
Lipstick on a pig I know but pigs need love too
To start, put the petcock valve to OFF and then remove the hoses going to and from the carburetor and drain the float bowl. There's a little valve on the bottom of the carb just for that purpose. With the gas tank removed, the KLR looks like any other bike:
Some ghetto wiring that I'll be replacing:
Removing the carburetor on a single is an easy job. The only trick is disconnecting the choke circuit. To do this, I removed the chock lever from the handlebar to give the cable housing some slack. It then unbolts off the carb body (its the brass thing under the cylinder head). The housing is PLASTIC!!! and easily damaged. Go Green! :uhg:
I pulled off the throttle cables and loosened the manifold and airbox clamps. A little wiggling and the carburetor slid right out.
This is by far the dirtiest carburetor I've ever rebuilt. It took a full can of carb cleaner to get this thing clean after taking it all apart! The jets and needle were placed in a parts dip for day and then blasted with more carb cleaner and then compressed air. All the other ports were given the same treatment.
More pictures to follow:
One of the things I did was shim the needle using a pair of #4 brass washers. I'm hoping that this helps my mid-throttle dead spot. I was happy to find that the jets were both OEM spec and that the fuel mixture screw was already adjusted out.
I replaced all of the phillips head screws with 4mm hex bolts. Two of the screws on the float bowl were mangled and had to be removed with vice grips
Lipstick on a pig I know but pigs need love too
05-20-2009, 09:17 AM
#4
Honda-Tech Member
Thread Starter
Re: Carburetor Rebuild
It's getting better. Some paint to cover up an old battery acid spill on the passenger peg/subframe and it will look even better
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