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Old 11-09-2013, 09:48 AM   #1
dirtwarrior
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Default KLR 650 jetting

Sorry I know this has been asked a lot but I am getting my KLR out to get a new clutch and jetting.
I am going to make a copy to give my mechanic.
With the hole saw mod to the muffler and no air box mod what is the closest ball park jetting to a 05 KLR 650?

Going to replace the clutch also so should I go stock or aftermarket?
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Old 11-09-2013, 06:27 PM   #2
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Default Re: KLR 650 jetting

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Originally Posted by dirtwarrior View Post
Sorry I know this has been asked a lot but I am getting my KLR out to get a new clutch and jetting.
I am going to make a copy to give my mechanic.
With the hole saw mod to the muffler and no air box mod what is the closest ball park jetting to a 05 KLR 650?

Going to replace the clutch also so should I go stock or aftermarket?
You can search under my name for all things jetting....I'd recommend the KLX needle kit as a great starting point.
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Old 11-09-2013, 07:24 PM   #3
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Default Re: KLR 650 jetting

Thank you for the reply. I did a search like you suggested and the search only turns up a max of 5 pages. I did a general jetting search. Then searched the threads you have made and also your post.
So far I did not find it.
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Old 11-10-2013, 02:28 PM   #4
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Default Re: KLR 650 jetting

If you are leaving the carb stock i.e. no KLX or aftermarket kit then simply do the .20 cent mod, uncap the fuel screw and turn it out to 2 turns. On the air box pull the snorkel. You are done...

I recommend the KLX kit or the JD Kit. I don't recommend the Dynojet (DJ) kit. While they make a great needle (good taper for the KLR) their included jets and other carb recommendations are wrong and leave the bike far too rich. With either of the other kits simply follow the included instructions. One other mod that I often do is drill the carb slide vac hole to 7/64". This will speed up the slide giving a bit quicker throttle response.

www.eaglemike.com is a great source for KLX kit and other KLR parts.

Hope that helps!
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Old 11-11-2013, 06:27 AM   #5
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Default Re: KLR 650 jetting

Thank you sir that helps a lot. I wish there was a sticky on the mods you just said.
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Old 11-11-2013, 07:19 AM   #6
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Default Re: KLR 650 jetting

I found this

Pilot Jet...leave as stock
Fuel Screw...2 turns out
Needle...leave the Dynojet on 2nd clip
Main Jet...Keihin 140 (stock is 148 and is WAY TOO rich w/ Dynojet needle)
Snorkle pulled

Would this get me close with snorkel mod in air box and low buck muffler mod?

Last edited by dirtwarrior; 11-11-2013 at 07:21 AM.
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Old 11-11-2013, 10:39 AM   #7
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Default Re: KLR 650 jetting

Do you have a Dynojet needle? If so then treat it as a KLX needle....2nd clip and either a 140 or 142 Keihin main jet. Do NOT lean out the main jet if you are still using the stock needle.
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Old 11-12-2013, 07:28 AM   #8
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Default Re: KLR 650 jetting

Let me ask this for a poor mans jetting
Get the KLX 650 needle from Kawasaki
Get the 140 jet from Harley

Drill the A/F plug to get at the screw
Pull the snorkel
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Old 11-12-2013, 10:05 AM   #9
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Default Re: KLR 650 jetting

You need more than just the klx needle to use it in a KLR.
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Old 11-12-2013, 11:12 AM   #10
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Default Re: KLR 650 jetting

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You need more than just the klx needle to use it in a KLR.
I am new to this as you can tell. What else do I need
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Old 11-12-2013, 12:28 PM   #11
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Default Re: KLR 650 jetting

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Originally Posted by dirtwarrior View Post
I am new to this as you can tell. What else do I need
Order the KLX kit from Mike- its $35. Most other jet kits cost twice that amount. Then you'll be completely set.
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-2004 KLR (blacked out with gloss)
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-"L" mod and snorkel removed (most of the airbox is "air" anyways)
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Old 11-12-2013, 03:28 PM   #12
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Default Re: KLR 650 jetting

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Originally Posted by dirtwarrior View Post
I am new to this as you can tell. What else do I need
You need to order the C clip and brass spacer in order for it to fit the KLR carb. www.eaglemike.com has a complete kit and instructions. Just to prevent post# 659 titled "Why wont my KLR run after installing the KLX kit" be sure that the brass spacer goes ON TOP of the needle clip. Not under as most assume... all else fails read the instructions twice

If you prefer to support your local dealer rather than a vendor here who happens to go way out of his way to help the KLR community here is the part numbers you'll need.

needle (N1TB #16009-1794), spacer (92143-1667) and clip (92037-1401
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Last edited by Chuck B; 11-12-2013 at 03:32 PM.
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Old 11-12-2013, 07:24 PM   #13
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Default Re: KLR 650 jetting

Thank you both
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Old 11-14-2013, 07:09 AM   #14
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Default Re: KLR 650 jetting

OK got the jetting issue straight now to the clutch. Stock or aftermarket. Seems the clutch grabs no matter what adjustment I make. If I start it in gear with the clutch in it lunges slightly. If in neutral and I put it in gear it lunges then dies.
After the bike warms a lot it will not do this.

Repair or replace??
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Old 11-14-2013, 10:21 AM   #15
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Default Re: KLR 650 jetting

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Originally Posted by dirtwarrior View Post
OK got the jetting issue straight now to the clutch. Stock or aftermarket. Seems the clutch grabs no matter what adjustment I make. If I start it in gear with the clutch in it lunges slightly. If in neutral and I put it in gear it lunges then dies.
After the bike warms a lot it will not do this.

Repair or replace??
Thats pretty typical of wet clutch designs. Some are worse than others and often oil brand can have a significant impact on making it worse or better. On bikes I've had in the past that were bad I'd leave the bike in gear and rock it back n forth (Edit: with clutch lever pulled) just before starting. This helps unstick the fibre plates from the steels.

If there is a physical problem with the clutch components having notched outer and/or inner basket arms will greatly increase the symptoms and also show up as the clutch feeling grabby when releasing.

I only use OEM components.... Regardless, try different oils, rocking the bike etc and do not blindly go ordering parts without first pulling the clutch apart and doing a full inspection/measurement. Don't forget pulling your clutch cable and inspecting closely...I've seen lots of money thrown at clutch problems only to have the owner find it was all due to a cable coming apart internally.

KLR clutch is WAY overbuilt for the KLR. Notched basket arms are due to very high mileage (normal wear) or owners who fail to inspect/replace the cush drive in the rear hub. As a general rule 25-30K is about normal interval to replace.
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Last edited by Chuck B; 11-14-2013 at 03:53 PM.
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Old 11-14-2013, 10:46 AM   #16
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Default Re: KLR 650 jetting

You sir are very knowledgeable and a money and time saver
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Old 11-21-2013, 06:24 PM   #17
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Default Re: KLR 650 jetting

Oil made a Huge difference on my 87 kawi 454. Stuck like crazy . Pulled it apart. A couple of times to deglaze plates but sticking came back. Completely fixed when I changed to shell rotella 15w/40 with the JASO MA (wet clutch) spec. (fine print on back of jug). Theres also a JASO MB spec, but I dont know if that's better or worse
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Old 11-21-2013, 06:30 PM   #18
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Default Re: KLR 650 jetting

I will try that oil
thank you
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Old 11-21-2013, 06:55 PM   #19
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Default Re: KLR 650 jetting

Quote:
Originally Posted by dirtwarrior View Post
I found this

Pilot Jet...leave as stock
Fuel Screw...2 turns out
Needle...leave the Dynojet on 2nd clip
Main Jet...Keihin 140 (stock is 148 and is WAY TOO rich w/ Dynojet needle)
Snorkle pulled

Would this get me close with snorkel mod in air box and low buck muffler mod?
I am ordering the Eagle Mike kit.

Instead of the holesaw mod on mufler I ordered a different one a DG O series
The above info on the jets is that still in the ball park.
Anyone got a link on drilling out for the fuel screw?
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Old 11-21-2013, 08:49 PM   #20
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Default Re: KLR 650 jetting

Quote:
Originally Posted by dirtwarrior View Post
I am ordering the Eagle Mike kit.

Instead of the holesaw mod on mufler I ordered a different one a DG O series
The above info on the jets is that still in the ball park.
Anyone got a link on drilling out for the fuel screw?
Under the Maintenance, Mods & Tech section you'll find Procedures & How to Articles. Lots of sticky's on all things KLR. Glenn (site owner) has one specifically on what you are looking for. I use a small drill bit to make a hole then screw in a wood screw and pull...only warning is don't drill too deep and done run the screw deep either.
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