Difficulty
Moderate
Steps
14
Time Required
1 - 2 hours
Sections
1
- 2002 Kawasaki KLR650 Carburetor Rebuild
- 14 steps
Flags
5
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Introduction
What you need
Step 1
2002 Kawasaki KLR650 Carburetor Rebuild
- Use a 3mm Allen wrench to loosen the drain screw on the lower part of the bowl.
- Dispose of the fuel left inside of the bowl properly.
Use a 3mm Allen wrench to loosen the drain screw on the lower part of the bowl.
Dispose of the fuel left inside of the bowl properly.
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Step 2
- Using 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.
Using 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.
Step 3
- Remove the pilot jet using a flat head screwdriver.
Remove the pilot jet using a flat head screwdriver.
Step 4
- Remove the main jet using a flat head screwdriver.
Remove the main jet using a flat head screwdriver.
Step 5
- Remove the main jet sleeve using an 8 mm combination wrench
Remove the main jet sleeve using an 8 mm combination wrench
Step 6
- Push out the retaining pin holding in the float and float seat.
- Remove this assembly from the carburetor.
Push out the retaining pin holding in the float and float seat.
Remove this assembly from the carburetor.
Step 7
- Flip the carburetor around and remove the four screws holding on the top housing using the Phillips #1 screwdriver.
- Note that this is spring loaded.
Flip the carburetor around and remove the four screws holding on the top housing using the Phillips #1 screwdriver.
Note that this is spring loaded.
Step 8
- Pull up on the diaphragm carefully to remove the diaphragm and slide.
- Take out the needle and plastic needle retainer.
Pull up on the diaphragm carefully to remove the diaphragm and slide.
Take out the needle and plastic needle retainer.
Step 9
- Replace the needle and reassemble the slide assembly.
- Insert the slide assembly back into the carburetor. Make sure the needle is 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 four Phillips screws in the housing since it is spring loaded. Tighten in a diagonal pattern to ensure that the plastic housing is sealed properly.
Replace the needle and reassemble the slide assembly.
Insert the slide assembly back into the carburetor. Make sure the needle is 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 four Phillips screws in the housing since it is spring loaded. Tighten in a diagonal pattern to ensure that the plastic housing is sealed properly.
Step 10
- Replace the old float seat with the new one 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.
Replace the old float seat with the new one 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.
Step 11
- Insert the new piolet jet into the carburetor. Tighten with a flat head screw driver.
- Do not over tighten as this is made of brass and may strip easily.
Insert the new piolet jet into the carburetor. Tighten with a flat head screw driver.
Do not over tighten as this is made of brass and may strip easily.
Step 12
- 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.
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.
Step 13
- Insert the new gasket into the bowl gasket groove.
- Screw the bowl back onto the carburetor with the four Phillips screws by using a Phillips #1 screwdriver. Tighten in a diagonal pattern to ensure that the bowl is sealed properly.
Insert the new gasket into the bowl gasket groove.
Screw the bowl back onto the carburetor with the four Phillips screws by using a Phillips #1 screwdriver. Tighten in a diagonal pattern to ensure that the bowl is sealed properly.
Step 14
- Tighten back up the drain screw at the bottom of carburetor using a 3 mm Allen wrench.
Tighten back up the drain screw at the bottom of carburetor using a 3 mm Allen wrench.
To reassemble your device, follow these instructions in reverse order.
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Author
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Shawn Marcoux
Member since: 03/24/2021
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Team
UMass Dartmouth, Team S1-G15, Riel Spring 2021
Member of UMass Dartmouth, Team S1-G15, Riel Spring 2021
UMASSD-RIEL-S21S1G15
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