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2002 Kawasaki KLR650 Carburetor Rebuild

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  1. 2002 Kawasaki KLR650 Carburetor Rebuild, 2002 Kawasaki KLR650 Carburetor Rebuild: passo 1, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild, 2002 Kawasaki KLR650 Carburetor Rebuild: passo 1, immagine 2 di 2
    • Use an 3 mm Allen wrench to loosen the drain screw on lower portion of bowl.

    • Remove old fuel left inside of bowl.

  2. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 2, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 2, immagine 2 di 2
    • Use a Phillips #1 screwdriver to remove the four screws on the outside of the bowl.

    • Remove the bowl from the carburetor and take out the gasket from the bowl.

  3. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 3, immagine 1 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 3, immagine 2 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 3, immagine 3 di 3
    • Remove the pilot jet using a flat head screwdriver.

  4. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 4, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 4, immagine 2 di 2
    • Remove the main jet using a flat head screwdriver.

  5. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 5, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 5, immagine 2 di 2
    • Remove the main jet sleeve using an 8 mm combination wrench.

  6. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 6, immagine 1 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 6, immagine 2 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 6, immagine 3 di 3
    • Push out the retaining pin holding in the float and float seat.

    • Remove this assembly from the carburetor.

  7. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 7, immagine 1 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 7, immagine 2 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 7, immagine 3 di 3
    • Flip the carburetor around and remove the four screws securing the top housing using a Phillips #1 screwdriver.

    • Note that this is spring loaded.

  8. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 8, immagine 1 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 8, immagine 2 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 8, immagine 3 di 3
    • Pull up on the diaphragm carefully to remove the diaphragm and slide.

    • Take out the needle and plastic needle retainer.

  9. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 9, immagine 1 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 9, immagine 2 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 9, immagine 3 di 3
    • Replace the needle and reassemble the slide.

    • Insert the slide assembly back into the carburetor.

    • The needle needs to be lined up with the hole in the carburetor. Make sure that the diaphragm makes a good seal in the carburetor gasket groove.

    • Insert the spring into the slide assembly and put the plastic housing back on.

    • Maintain pressure while screwing the four Phillips screws in the housing since it is spring loaded.

    • Tighten the screws in a diagonal pattern to ensure that the plastic housing is sealed properly.

  10. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 10, immagine 1 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 10, immagine 2 di 3 2002 Kawasaki KLR650 Carburetor Rebuild: passo 10, immagine 3 di 3
    • Place the new float seat onto the float.

    • Place the float assembly into the carburetor and slide the retaining pin back into its hole to secure the assembly.

    • Make sure that the float can move freely.

  11. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 11, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 11, immagine 2 di 2
    • Insert the new pilot jet into the carburetor. Tighten it with a flathead screwdriver.

    • Do not over tighten the pilot jet as it is made of brass and may strip easily.

  12. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 12, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 12, immagine 2 di 2
    • Reinsert the main sleeve and tighten with an 8 mm combination wrench.

    • Insert the new main jet into the main jet sleeve. Tighten using a flathead screwdriver.

    • Do not over tighten as this is made out of brass and may strip easily.

  13. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 13, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 13, immagine 2 di 2
    • Insert the new gasket into the bowl gasket groove.

    • Use a Phillips #1 screwdriver to replace the four screws securing the bowl to the carburetor.

    • Tighten in a diagonal pattern to ensure that the bowl is sealed properly.

  14. 2002 Kawasaki KLR650 Carburetor Rebuild: passo 14, immagine 1 di 2 2002 Kawasaki KLR650 Carburetor Rebuild: passo 14, immagine 2 di 2
    • Use a 3 mm Allen wrench to tighten drain screw at the bottom of carburetor.

Conclusione

To reassemble your device, follow these instructions in reverse order.

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