2002 Kawasaki KLR650 Carburetor Rebuild

Introduction

If your 2002 Kawasaki KLR650 Carburetor needs to be rebuilt to better control the the air and fuel entering the engine-please use this guide to replace it. Please inspect all parts before starting this project. In addition, safely remove all old fuel and dispose of according to your local laws.

Removing the bowl and taking the gasket out of the bowl will be your first step in aiding to better control the air and fuel.

A couple of warnings before you begin:

In step 7 note that the top housing is spring loaded.

In step 11 don't over-tighten the pilot jet as it is made of brass and may strip easily.

What you need

Step 1 2002 Kawasaki KLR650 Carburetor Rebuild

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2002 Kawasaki KLR650 Carburetor Rebuild, 2002 Kawasaki KLR650 Carburetor Rebuild: step 1, image 2 of 2

Use an 3 mm Allen wrench to loosen the drain screw on lower portion of bowl.
Remove old fuel left inside of bowl.

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Step 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.

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Step 3

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Remove the pilot jet using a flat head screwdriver.

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Step 4

Remove the main jet using a flat head screwdriver.

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Step 5

Remove the main jet sleeve using an 8 mm combination wrench.

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Step 6

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Push out the retaining pin holding in the float and float seat.
Remove this assembly from the carburetor.

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Step 7

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Flip the carburetor around and remove the four screws securing the top housing using a Phillips #1 screwdriver.
Note that this is spring loaded.

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Step 8

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Pull up on the diaphragm carefully to remove the diaphragm and slide.
Take out the needle and plastic needle retainer.

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Step 9

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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.

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Step 10

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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.

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Step 11

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.

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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.

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Step 13

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.