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-   -   KLX250s exhaust and jetting (https://www.kawasakiforums.com/forum/general-tech-9/klx250s-exhaust-jetting-30425/)

jeffzx9 10-05-2009 04:27 PM

Um, turn that little "switch-looking-thingy" that says "on-off-reserve."

slippery750 10-05-2009 04:37 PM


Originally Posted by KLX250SF (Post 395946)
I just put a Two Bro slip on exhaust on my KLX250SF. I really like the sound of it and it runs great UNTIL I get about 5 miles in on a steady 55 mph ride and it stalls like it is out of gas. I did not rejet and I assume the new pipe with the increase flow through is really throwing off my fuel mixture and when it gets good and hot it chokes out the carb?

You need to get the Dynojet kit and install it. Another cause could be a plugged tank vent line. Does your bike have the smog stuff on it? Does it have a black cylinder mounted below the horn to the frame/front motor mount?

klx678 10-06-2009 12:14 AM

Another possibility that will compensate for the lean jetting along with most any change in altitude and temperature is to install the Dial-A-Jet kit for a single. It works on the same principle as the Mikuni's powerjet, siphoning in fuel/air mix when a lean condition causes a vacuum - which it does. I've used it since 97 on my KLX without any jetting changes. I've added a full exhaust, a big bore Vulcan piston, and opening up the air box. It also has no problem compensating for temps from 20-95 degrees (what I've ridden in) and from sea level at Daytona BikeWeek to about 5000 feet in the mountains of West Virginia - no adjustments, center setting all the way.

I learned of the Dial-A-Jet back in the mid 80s and had them in my 86 Nighthawk S to eliminate the flat spot in the carburation. The Dial-A-Jet is much more accepted in the ATV and snowmobile markets, which I would attribute to the fact that they grew at about the same time as the Dial-A-Jet came out. Check them out at http://www.thunderproducts.com/dial_a_jet.htm and read the product evaluations by Motorcyclist and Dirt Bike as well as some of the product testimonials. I've gotten a number of KLX riders using them and a friend had great results on his XT225. It simply works well without having to tear down and rejet until it works right.

I did the jetting thing on my old flat tracker and mx bikes, but since 1986 I will do the Dial-A-Jet first for the price, ease of installation, and results. The plug is always a nice proper brown and the pipe tip indicateds a good burn.

KLX250SF 10-06-2009 01:07 PM

Thanks for the info klx678, I will have to check into the dial a jet. I ran into a friend of mine that recommended that as well.

I am going to check out the tank vent line as well. I have a full tank and I am not on the reserve :) I didn't expect that just adding the slip on would make the bike stall out like it was out of gas.

Thanks again!

slippery750 10-06-2009 10:25 PM

Yeah thanks klx678 I will be checking it out too, first I've heard about these.

Linebacker505050 10-08-2009 07:29 PM

I just got my bike back and the dynojet really opened it up. I am extremely happy with the increase in acceleration and power. Didnt have much time to ride but i'm taking it out this weekend and cant wait. However i am not very happy about the fact that i didnt do it myself. live and learn i guess.

Dragone#19 10-08-2009 08:51 PM


However i am not very happy about the fact that i didnt do it myself. live and learn i guess.
Babysteps sometimes can be more beneficial. So did you mark down in your manual any and all changes that were made to your ride? That always comes in handy. Congrats on your newly tuned ride. Enjoy


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