I finally got my carb mods sorted out on my KLR.  BIG difference!!!  For those that don't know, the hot setup as quoted on multiple web pages is as follows:

- Cut the airbox.  You can see the procedure at http://dualsportride...930&page_id=170
I also removed the wire screen in the airbox.  It's purpose and usefulness have been debated on many boards.  I'm not really concerned about a fire in my airbox due to backfire (when was the last time you heard of that one?).  Also, I have always thought that less obstruction equals more air, so away it went.
-160 main jet
-42 pilot jet
-drill the slide vaccuum hole to 1/8"
-pull the plug on the air mix screw and back out 2-1/2 turns.
-Shim the stock needle up .06-.07".  I went with three M3 washers.  Worked perfect.
-UNI air filter

Besides the backfire screen, these mods have also been debated many times on different boards.  My personal experience was that this made a noticeable difference in throttle response as well as getting rid of flat spots through the band.  I can now easily lift the front wheel by a quick snap of the throttle.  I could never do that before.  The Dynojet kit does the same thing for around $60, but I did this whole procedure for about half that.  The filter was about $20, and the two jets ran about $8.  I also run a Supertrapp IDS with 10 disks.  I have a whole new bike!!!!         

Cool!  Beautiful feeling isn't it?       At some point, you might like to try the dynojet kit though.  Although it costs some more $$ the profile of the needle is superior to the shimmed stock needle.  Still, it's nice to open it up isn't it.  That's how they should come stock.   

He didn't mention it, but I believe that the carb mods were to a KLR650.

Ride on
Brewster

Bill_P said:

The KLX needle is also more tapered than the KLR needle, and uses a clip as well as the Dynojet.  Since I'm CHEAP (like most KLR riders) I'll stick with this for now.  

brewster said:

Yes, KLR 650.   I always forget there's a 250 out there too.  

160 main jet?, Others on these boards have said a 150 even is to rich,Im also seeing 140 by some members,Im guessing every ones at different elevations?thats all I can think of for such a wide spread on the jets.Ill try the 140,and tune from there,but 160?sure seems drastic.

Edited by XR_RON, 09 February 2012 - 02:20 PM.

XR_RON, on 09 February 2012 - 02:17 PM, said:

you see back in 2005 the air was denser

What size jets do people run on the 650 at the 5200 ft level?

ya gotta know who's jet you have too..... Kehin, Mikuni, and Dynajet all look the same & fit the hole but have different flow rates for the same number. I have a chart somewhere....

Like this one found on another forum?

Here is a jet conversion chart


Width------Keihin # -- DynoJet # -- Mikuni #
0,0350---- 92,5--------- 92----------- 86,3
0,0360---- 95----------- 94----------- 88,1
0,0370---- 97,5--------- 96----------- 90,0
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
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
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
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
0,0700---- 180--------- 162--------- 151,9
0,0710---- 182,5------- 164--------- 153,8
0,0720---- 185--------- 166--------- 155,6
0,0730---- 187,5------- 168--------- 157,5
0,0740---- 190--------- 170--------- 159,4
0,0750---- 192,5------- 172--------- 161,3
0,0760---- 195--------- 174--------- 163,1
0,0770---- 197,5------- 176--------- 165,0
0,0780---- 200--------- 178--------- 166,9
0,0790---- 202,5------- 180--------- 168,8
0,0800---- 205--------- 182--------- 170,6
0,0810---- 207,5------- 184--------- 172,5
0,0820---- 210--------- 186--------- 174,4
0,0830---- 212,5------- 188--------- 176,3
0,0840---- 215--------- 190--------- 178,1
0,0850---- 217,5------- 192--------- 180,0
0,0860---- 220--------- 194--------- 181,9
0,0870---- 222,5------- 196--------- 183,7
0,0880---- 225--------- 198--------- 185,6
0,0890---- 227,5------- 200--------- 187,5

I've got the 1985 KLR600 its got the slide drilled same as 650, 2x 0.6 mm washers under the needle 150 main jet, mixture screw 2.1/4 turns out, K&N pannel filter in box with rubber intake silencer removed and a home made aluminium lid made to stop all the crud going in, Arrow dakar exhaust tail pipe fitted 16 tooth front sprocket and Metzler Turance tyres 75% road 25% off road (less drag. My bike will top 100mph and gets thair fast would pull wheelies easey but thats just not my bagg. I would say its quicker than the 650 becaus it only weighs 130Kg its like a striped down version of a KLR650 for those who have never seen one. take a look. (http://www.bikez.com...lr_600_1985.php)

Edited by LordYorkshirePuding, 04 March 2012 - 02:10 PM.

Is it me? It sees as soon as I add my bit to a thred it kills it dead. Mabe im from the wrong side of the pond or just becaus I have an older bike with 50cc less not to sure but no one ever carries on after I make a comment. Mabe I'm just paranoid!! //(*_*)

slide drilled same as a 650.... what size? same as a 650 stock or an over drilled 650

LordYorkshirePuding, on 04 March 2012 - 02:08 PM, said:

Like they say: just because you're paranoid doesn't mean they aren't out go get ya!

I like the looks of the bike in the link you gave above.  Any pics of your bike?

I've heard drilling the slider to 7/64", and the first post is 1/8".  What did you drill yours to and is that the same as for 650s?  I just got my 650 a couple months ago.  It seems mostly stock except for a K&N filter and very faded red plastics so I'm looking forward to some mod work on her.  There's a big pile of parts setting in the garage (skid plate, center stand, nerf bars, highway bar, gravity petcock, hand guards, grip heaters, clutch lever, etc) but now I'm laid up recovering from a broken femur and can't do much of anything.  wahh.

LordYorkshirePuding, on 04 March 2012 - 03:02 AM, said:

I had an 85 XL 600r,and it would hit 100 mph also,specs said 43 rwhp.

LordYorkshirePuding, on 04 March 2012 - 02:08 PM, said:

Sorry about my crazy rant I was just feeling that way out I am but a crazy fool LOL

Slide drilled 3mm which is sort of in the middle between 7/64 and 1/8. it just made the throttle snap open a bit quicker

7/64 is 2.7781mm and 1/8 is 3.1750mm
This is a pic of my KLR600 (http://www.bikez.com...=15461&pageno=2)

LordYorkshirePuding, on 08 March 2012 - 09:13 AM, said:

So was the slide drill the only mod you made at this time?  Just wondering if the drill really made a noticable difference on its own.  Nice looking bike.

Edited by IDRIDR, 08 March 2012 - 03:59 PM.

I found that becaus the slide lifted quicker at lower revs it needed the needle lifting to avoid a flat spot around 4500 rpm. Because the slide lifts with slightly less air flow it lifts the needle out but thair is not enough air flow to lift the fuel hence putting washers under the needle and 150 jet also my exhaust is quite free flowing like a big gun so this all compounds the effect. the answer to your question is that with everything else done to make it all work you get big pulling power from 2500rpm to 5500 and when you blip the throttle it revs instantly its hard to describe I hope this helps I had to play around quite a lot to get it all working I started on a 140 main jet and worked up lifting and lowering the needle and ajusting the mixture screw so be prepaired to play whith it. I still keep tweeking bits

That all makes sense, thank you.
I've yet to even have the carb out the of the KLR yet.  I just put the 351 kit in the KLX, so my efforts are focused on getting the jetting all fine tuned with that machine before shifting focus to the KLR.  So I'm trying to get my mind all wrapped around all the different approaches and figure out what all I need to do (the list is very long; this is going to be a serious project).  I'm ready to tinker until its right.

Thanks!

LordYorkshirePuding, on 04 March 2012 - 02:08 PM, said:

Just becaue your fromt he other side doesn't mean anything.  Although you guys talk funny and drive on the wrong side of the road.    although your KLR is kawi green.  I'd love a green fairing.

LordYorkshirePuding, on 04 March 2012 - 02:08 PM, said:

I have a KLR600.  I love it so far.  A have all the traditional mods.  .22, klx needle, drilled slide still woriking on tuning.  Keep in mind its not 50cc les.  The KLR 600 is actuall a 564 so its 86 cc's less.  I'm going to do a port an polish next year and try to come up with an overbore for it.  I just need a spare top end to play with.