22 cent mod fine tuning

HILDI1685 · Aug 3, 2011

I threw a UNI Filter in my 02 KLR650, Drilled 4 holes in the top of the airbox, shimmed the needle .040 and backed the air/fuel screw out 2 1/4 turns. Wow! on the low end, but acts fuel starved at highway speeds (60mph+). Flipping on the choke makes it run good at speed. What do you all suggest?

Thanks, Scott

Nico · Aug 3, 2011

A new Tiger 800.

Or a bigger main from the sound of it. Not a KLR guy though, so maybe wait till the rest of the crew gets here.

booger1 · Aug 3, 2011

Looks like you opened up the air flow alot. Hows the exhaust and did you go to a larger jet?

HILDI1685 · Aug 3, 2011

Stock jet...for now, and I have untweeted the exhaust with a big screwdriver and a hammer. A quiet pipe is on my short list.

Beezer · Aug 3, 2011

sounds like time for a bigger main jet. just be careful who's jet you put in... every brand has a different flow for the same number.

 Kawasaki jet numbers:
Stock jet = 148 p/n 92063-1324
150 p/n 92063-1330
152 p/n 92063-1331

something I got off the net somewhere.... won't promise it is accurate.

 [FONT=&quot] [/FONT]
CARB JET CROSSOVER:
[FONT=&quot]Hole Dia---Keihin # -- DynoJet # -- Mikuni #
0.0350---- 92.5--------- 92----------- 86.3
0.0360---- 95----------- 94----------- 88.1
0.0370---- 97.5--------- 96----------- 90
0.0380---- 100---------- 98----------- 91.9
0.0390---- 102.5------- 100---------- 93.8
0.0400---- 105--------- 102---------- 95.6
0.0410---- 107.5------- 104---------- 97.5
0.0420---- 110--------- 106---------- 99.4
0.0430---- 112.5------- 108--------- 101.3
0.0440---- 115--------- 110--------- 103.1
0.0450---- 117.5------- 112--------- 105
0.0460---- 120--------- 114--------- 106.9
0.0470---- 122.5------- 116--------- 108.8
0.0480---- 125--------- 118--------- 110.6
0.0490---- 127.5------- 120--------- 112.5
0.0500---- 130--------- 122--------- 114.4
0.0510---- 132.5------- 124--------- 116.3
0.0520---- 135--------- 126--------- 118.1
0.0530---- 137.5------- 128--------- 120
0.0540---- 140--------- 130--------- 121.9
0.0550---- 142.5------- 132--------- 123.8
0.0560---- 145--------- 134--------- 125.6
0.0570---- 147.5------- 136--------- 127.5
0.0580---- 150--------- 138--------- 129.4
0.0590---- 152.5------- 140--------- 131.3
0.0600---- 155--------- 142--------- 133.1
0.0610---- 157.5------- 144--------- 135
0.0620---- 160--------- 146--------- 136.9
0.0630---- 162.5------- 148--------- 138.8
0.0640---- 165--------- 150--------- 140.6
0.0650---- 167.5------- 152--------- 142.5
0.0660---- 170--------- 154--------- 144.4
0.0670---- 172.5------- 156--------- 146.3
0.0680---- 175--------- 158--------- 148.1
0.0690---- 177.5------- 160--------- 150
0.0700---- 180--------- 162--------- 151.9
0.0710---- 182.5------- 164--------- 153.8
0.0720---- 185--------- 166--------- 155.6

[/FONT]

HILDI1685 · Aug 4, 2011

Good info! So...if I found a dynojet kit, what size should I try?

Beezer · Aug 4, 2011

a Kehin 150 is a Dyno 138 by the chart. I'd go up one & try it. BTW, Dynojet jets are about $4-5 and Kawasaki (Kehin)are about $10.

Also, if you haven't done it already change the screws in the rubber manifold block to bolts. Then you can pull the carb with the block & it's way easier. See if you can find some case bolts that have the small heads.

Xcuvator · Aug 4, 2011

When you shim the needle, you should also drill the slide vent hole. I would do that before you start changing jets. Going to the KLX needle does more for you than shimming the stock needle, but does require a leaner main jet.
Here is a link that should help you with the slide:
http://klrworld.com/forums/index.php/topic,1380.0.html

TortillaJesus · Aug 8, 2011

Xcuvator said: ↑

When you shim the needle, you should also drill the slide vent hole. I would do that before you star changing jets. Going to the KLX does more for you than shimming the needle but does require a leaner main jet.
Here is a link that should help you with the slide:
http://klrworld.com/forums/index.php/topic,1380.0.html
Click to expand...

Definitely this!!

HILDI1685 · Aug 8, 2011

Thanks for the advice. I did drill the slide while I had it apart. What a difference! I'm thinking I will add a pipe!

Gray_Rider · Aug 9, 2011

I had a similar problem with the 22c mod. Couldn't get the bike to rev pass 6 grand.

I guess the PO had already rejetted it, so the shims were too much. I pulled them back out to fix it.

If you are not the first owner, you may have to consider some one may have already rejetted, as they come lean from the factory.

Kawidad · Aug 9, 2011

Pussboy said: ↑

Thanks for the advice. I did drill the slide while I had it apart. What a difference! I'm thinking I will add a pipe!
Click to expand...

Be aware that if you pipe it, you'll have to richen up the jetting to accommodate the change in flow. Usually richer pilot jet, needle positioning, and main jet.

RevBill · Aug 10, 2011

Beezer said: ↑

sounds like time for a bigger main jet. just be careful who's jet you put in... every brand has a different flow for the same number.

 Kawasaki jet numbers:
Stock jet = 148 p/n 92063-1324
150 p/n 92063-1330
152 p/n 92063-1331

something I got off the net somewhere.... won't promise it is accurate.

 [FONT=&quot] [/FONT]
CARB JET CROSSOVER:
[FONT=&quot]Hole Dia---Keihin # -- DynoJet # -- Mikuni #
0.0350---- 92.5--------- 92----------- 86.3
0.0360---- 95----------- 94----------- 88.1
0.0370---- 97.5--------- 96----------- 90
0.0380---- 100---------- 98----------- 91.9
0.0390---- 102.5------- 100---------- 93.8
0.0400---- 105--------- 102---------- 95.6
0.0410---- 107.5------- 104---------- 97.5
0.0420---- 110--------- 106---------- 99.4
0.0430---- 112.5------- 108--------- 101.3
0.0440---- 115--------- 110--------- 103.1
0.0450---- 117.5------- 112--------- 105
0.0460---- 120--------- 114--------- 106.9
0.0470---- 122.5------- 116--------- 108.8
0.0480---- 125--------- 118--------- 110.6
0.0490---- 127.5------- 120--------- 112.5
0.0500---- 130--------- 122--------- 114.4
0.0510---- 132.5------- 124--------- 116.3
0.0520---- 135--------- 126--------- 118.1
0.0530---- 137.5------- 128--------- 120
0.0540---- 140--------- 130--------- 121.9
0.0550---- 142.5------- 132--------- 123.8
0.0560---- 145--------- 134--------- 125.6
0.0570---- 147.5------- 136--------- 127.5
0.0580---- 150--------- 138--------- 129.4
0.0590---- 152.5------- 140--------- 131.3
0.0600---- 155--------- 142--------- 133.1
0.0610---- 157.5------- 144--------- 135
0.0620---- 160--------- 146--------- 136.9
0.0630---- 162.5------- 148--------- 138.8
0.0640---- 165--------- 150--------- 140.6
0.0650---- 167.5------- 152--------- 142.5
0.0660---- 170--------- 154--------- 144.4
0.0670---- 172.5------- 156--------- 146.3
0.0680---- 175--------- 158--------- 148.1
0.0690---- 177.5------- 160--------- 150
0.0700---- 180--------- 162--------- 151.9
0.0710---- 182.5------- 164--------- 153.8
0.0720---- 185--------- 166--------- 155.6

[/FONT]
Click to expand...

.. I knew this list existed .. thanks for posting it up .. just what I needed to know .. awesome ..

RevBill · Aug 10, 2011

Xcuvator said: ↑

When you shim the needle, you should also drill the slide vent hole. I would do that before you start changing jets. Going to the KLX needle does more for you than shimming the stock needle, but does require a leaner main jet.
Here is a link that should help you with the slide:
http://klrworld.com/forums/index.php/topic,1380.0.html
Click to expand...

.. read this once before and lost it .. thanks ..

schaffer40 · Aug 10, 2011

I did all that you have except drilling the airbox. It ran really good from the start. No trouble at speed. I did put a pipe on (Vance & Hines XCR) with no noticeable improvement with the stock engine. Biggest benefit of changing the pipe was loosing some weight. You also might want to try sealing the holes in the airbox (duct tape) temporarily to see if that improves the top end.

PacificPT · Aug 28, 2011

Beezer,

Thanks for posting the chart. I have a pipe and jetting kit ordered, having the list should be helpful.

HILDI1685 · Aug 29, 2011

schaffer40 said: ↑

I did all that you have except drilling the airbox. It ran really good from the start. No trouble at speed. I did put a pipe on (Vance & Hines XCR) with no noticeable improvement with the stock engine. Biggest benefit of changing the pipe was loosing some weight. You also might want to try sealing the holes in the airbox (duct tape) temporarily to see if that improves the top end.
Click to expand...

This was the key to really dialing it in! I put the plastic cover back over the end of the snorkel and that made an improvement. Then I plugged 2 of the 4 holes and that really helped! I will mess with it more once I get my pipe. Thanks for all the help!

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