How To Rebuild the Carburetor on a Kawasaki KLR650

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Carburetor components can get gummed up quickly, especially with today's low quality fuel. So if your KLR is leaking fuel or just running poorly, especially after extended periods of sitting, chances are your carburetor could use a good cleaning and rebuild. In this video, Charles shows how to remove, clean, and rebuild the carb on a Kawasaki KLR650.
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[@cbCONCRETEPUMPER]

Also you can burn the plastic off a bread tie and it's perfect for cleaning your pilot holes

[@danmanthe9335]

Next time I have to pull my carb off I'm going to have you do it. You swore a lot less

[@jaredpeiser2755]

THANK YOU THANK YOU THANK YOU!!! This is exactly the video I needed. Young mechanic in the making here.

[@tahoehookup]

Was well worth the view!!!!!

[@ianferrier235]

Thanks man. Glad to see you do it with the klr👍🏻👍🏻

[@troyzerna6337]

You make it look easy

[@donr416]

Very thorough. Thanks.

[@jawaman24]

Great video! Thanks!

[@acrew30]

Gracias amigo excelente vídeo que muestra detalladamente paso a paso como se baja se desarma y viceversa un carburador me va a servir mucho cuando me toque hacerle mantenimiento al carburador de mi moto saludos. Thank you, my friend, an excellent video that shows in detail step by step how it is dismantled and vice versa a carburetor will help me a lot when I have to do maintenance on the carburetor of my motorcycle greetings

[@patrkbukly4240]

Well done.

[@brucesturgeon4801]

Great video you make it look easy mate.

[@-WhizzBang-]

Except he didn't even bother mentioning that the Carb HAS to be TUNED properly after you put it back in the bike. This is VERY important, otherwise the bike won't run properly, and it could damage the engine! And you need to know what you are doing for this!

[@hascg1]

Excelente gracias saludos desde paraguay

[@millermike5739]

I bought all my stuff from you guys when i rebuilt my klr. You guys sent me an atv seat cover instead of a klr seat cover. Still upset all these years later lol 😭

[@CarlLarsonSeattle]

Excellent

[@ChrisTrevitt]

So Good!

[@vinceyreay]

My '98 model has an integral brass overflow pipe poking up from the inside of the float bowl, which has split....I'm in the process of removing the pipe & blocking the hole to prevent fuel pissing out.

[@mikebee969]

Awesome

[@rhllnm]

Take the fuel screw cap off and buy a finger adjustable screw on Ebay for $12.00. Had mine clog up in the desert, now I can adjust and clean easily on the trail.

[@And_rew92]

Or you just get an All Balls rebuild kit which comes with a longer screw

[@zieghaschel4497]

Awesome video! My klr will crank and run but I have to give it fuel to keep it running. It will die if I let it idle by itself

[@REPVILE]

Start with the pilot jet. Mine would run on choke but die if let up off the choke. Pilot jet was gummed up from some old shitty fuel.

[@KLR-650]

Never drain the carb on my 09. Not had a problem, but I always store it with non oxy.

[@trizman77]

are all of the float valves spring loaded ? mine seems to be the original 1997 and one machined piece.

[@TheHortond]

Use a strand of copper wire from an electric wire. The copper is softer than the steel and shouldn't hurt the jet while poking out junk.

[@mrkihn]

can you replace the slider diaphragm? mine got damaged on the outer edges. Having problems getting bike above 65 mph. KLR runs good but just won't go any faster than 65 mph

[@Spagghetii]

Use extra care when installing the mixture needle, make sure its seated properly before tightening. It can be tricky because of the spring, I gave mine a turn but it squashed the needle.

[@-WhizzBang-]

You don;t just rebuild the carb then throw it back in the bike, and go.....The carb also needs to be tuned properly when you put it back in the bike! He mentioned NOTHING about this! In my opinion, unless you really know what you are doing, rebuilding a carb should be left to a Professional!

[@ernsan1]

Very very helpful video, I just bought a 2006 KLR and I’m having problems to start it, it was sitting for a year, what do you recommend to do besides the carburetor. It’s my first bike

[@Mytyweav]

Ernesto, you will probably have to clean out the Fuel Valve under the tank also. I had both the Carb and the Tank Fuel valve get gummed up at the same time.

[@jethrolionheart182]

I recently bought one myself and it had the same issue I just drained the fuel changed the sparkplug and made sure my choke was right and it fired right up had sat 3 years

[@f1flick]

So I am frustrated. Float bowl was the only part acting up but since I had a rebuild kit I put everything in. Now it won’t run off of idle. Idles fine. Thanks.

[@Dieselpwr]

It would be nice if you can get a kit that actually has everything all the rubber and plastic

[@waynewhittal806]

I just bought a klr from a guy and I has been standing for quiet some time the bike runs but at around 4-5000rpm it's splutters quite badly what would be recommended?

[@karmaline]

Great video thank you! My bike sat for three years with the float bowl full. I did exactly what you said clean it thoroughly the carb and then put it all back together. Start it up great but now I have an issue where the RPM tack fluctuates from 50 to 100 RPMs back-and-forth , I tried adjusting the fuel mix screw every way in which Way but it does not go away. Do you have any ideas with this may be any help is greatly appreciated as I am not a mechanic. Thank you very much.

[@-WhizzBang-]

The carburetor has to be tuned for proper fuel to air mixture, after you rebuilt it and put it back in the bike. It isn't as simple as he makes it out to be in this video! And he doesn't even bother mentioning this, which is a very IMPORTANT part! This is WHY it is a job best left to a professional if you don't know what you are doing. You will probably have to take it to a shop to get this done properly! Otherwise, your bike won run right and you could cause damage to your engine!

[@nighthawkj30A4]

I used Silicone paste on the Rubber parts and o rings it make them last longer.

[@protectork9831]

Can you guys do a video for xr400r carburetor

[@xxxstonie]

kzbin.info/www/bejne/noCXYniLrN6oqrc

[@mikeandre7364]

Could you use an acupuncture needle to clean? They come in both silver and copper coated, and are extremely thin, so do you think it could be done? Or would the silver or copper affect the metal hose?

[@jaybo2112ot]

oh yeah, we all have acupuncture needles laying around the house.

[@davrog3918]

I also have a frayed throttle cable at the carb-best tips for that fix?? -Mahalo!

[@rmatvmc]

People have used solder to fix frayed cables so if you have the ability you can try that. But your best bet would be to replace the cable.

[@guitarman376]

Instead of draining the float bowl, would it work to turn the petcock to the off position and run the engine until it dies?

[@jaybo2112ot]

If you are at the point of pulling the carb, your engine probably wont run.

[@pdx650]

I do have a question about the fuel mixture screw at elapsed time 18:32. During removal, the repairer/maintainer had to count the rotations to remove the screw. There was nothing noted about seating it/bottoming it down before removal. It seems as though you need to know the rotations to get it seated during install and then subtract the number of rotations from the removal rotations to know where the needle is supposed to be (backing it off) at during normal operation.

[@xxxstonie]

1. All the way in. Count the rotations. 2. Unscreww. 3. After cleaning.... Screw it all the way in, and out according to step 1.

[@-WhizzBang-]

You don't just rebuild a carb then throw it back in the bike and go! It NEEDS to be TUNED properly, which is not always easy and you need to know what you are doing! . He mentions NOTHING about this! In my opinion, unless you know EXACTLY what you are doing, I would leave the rebuilding of a carb to a Professional! Otherwise, it could end up costing you even MORE money in the end!

[@mariaangelova4833]

pilot jet ° ?

[@xxxstonie]

To clean the Jet's, you could use Fishing Line instead of metalwire...

[@jaybo2112ot]

How do you push fishing line thru a plugged jet?

[@xxxstonie]

@@jaybo2112ot a plugged jet ! Goo builds up inside.... It should be soft. If totally clugged...... Well use a piece of cobberwire.... Its just to prevent scratching. Also some strains from a cloth would do the job. Run/pull the clothstrains through the jet. Effectively like grinding but with very smoth sandpaper..... Or like cleaning a pipe (smoking) with pipecleaners. Hope I made my self understanable. 😁

[@someguy5035]

But did it fix the bike?

[@Thewarhorse47]

Does anyone know if I can get the carb out and back in with the tank and seat still on?

[@goneballistic]

You can't they both have to come off

[@danielszewczuk1372]

te olvidaste de limpiar el micro filtrin in line en la entrada de combustible en el carb.

[@jackstephen4240]

Is it the same for a klx650?

[@xxxstonie]

Yes. CVK - CV40

[@larryjanson4011]

good video. but one item that needs to be said. the two plastic hose connections on the side. are the same. might be different colors but are 100% interchangeable. so keep a spare one in your kit.

[@allrock1238]

When replacing the diaphragm slide make sure the 2 dimples in the slide surface face the carburetor air inlet from the air box, please clarify if its possible to install the slide the wrong way around .

[@protectork9831]

You can install it wrong way but in all videos that I have seen they recommend to do it right

[@xxxstonie]

00:19:05 The dimple points towards the intake. That's a good reminder.

[@REPVILE]

Missed an opportunity to show how to reconnected fuel and vacuum hoses.

[@rmatvmc]

You're right, that would've been helpful. Thank you for the feedback and for checking out the video!

[@pythonplunger323]

You did not replace the fuel mix screw, don't think the KLR will run so good...

[@iwasadeum]

This is why I will never purchase anything that's not fuel injected lol

[@copisetic1104]

Until you in some backwoods in Mexico or South America, a carb you can fix, with fuel injection your screwed. Most guys that are serious about south of the border riding won’t ride fuel injected KLR’s

[@hacunamatata6802]

guy explains trailside carb cleaning, apparently gassed up with some water in the gas kzbin.info/www/bejne/qoTYpIapgZVslZo Not going to fix a fuel injected mc trailside that has this kind of problem.

[@Ryan-wr4nx]

Now show the hard part putting it back in

[@Greenpeace465]

anyone else catching a buzz from that carb cleaner ?

[@rmatvmc]

Please ventilate your work area!

[@-WhizzBang-]

The carburetor has to be TUNED after you rebuild it and put it back in the bike, and this is not a simple process. MY ADVICE: Unless you REALLY KNOW WHAT YOU ARE DOING, I would leave rebuilding your carburetor to a Professional! It may cost you some money, but it will save causing damage to your engine because you ran a carburetor that was not properly tuned!

[@pinkeye00]

Can't you just throw this in an ultrasonic cleaner for 3 hours and walk away?

[@MainelyMoto207]

That's not a monocle, it's a loup you hillbilly. Lol

[@-WhizzBang-]

DUDE!!!!!! The carburetor has to be properly TUNED after you rebuild it and place it back in the bike, you mentioned NOTHING about this, which is a very important step and usually has to be done by a professional or at least someone who knows what they are doing!~

[@cbCONCRETEPUMPER]

You know why your carb looks like a green goblin came in it? Because you put fuel stabilizer in it.. never use fuel stabilizer, just clean your carb once a year

[@kc2shw]

Yup let's block the view of how all the important needles need to go back in. Took the dam thing apart and can't get it together because of direction issues of your hands No thanks