Just got a 2001 KLR250. It has a broken KACR, so I removed the swing bit to run some tests while I wait for a new camshaft to arrive.

Basically my problem is that I can’t get it to start. I did read not having a KACR makes it hard to start, but not impossible I guess.

Things I tested so far:
- Has good blue spark on crank. Both on spark tester and spark plug.
- Timing is as per manual. No timing issues.
- Carbs have been striped and cleaned.
- Using brand new petrol
- Compression test. On good crank from TDC gives 60psi. 3 good cranks in sequence gives around 100psi

It seems I can’t get petrol inside the cylinder. After a few cranks when I remove the spark plug it is dry. It is dry if I have coil connected or not.

I could get one good combustion when sprayed starter fluid directly into the intake manifold.

I hooked up carb outlet to my vacuum cleaner to check suction. Main jet, pilot jet and choke are all squirting petrol as expected.

Could notice some pop-back on the carbs. Not sure what that means if I do have good compression, correct timing and correct valve gaps.

Is there anything else would you guys recommend trying? Or it is useless to try until I install the new camshaft?

 

I'd check valve clearances before ordering anything.

 

Valve clearances are good. They are fully retracted on TDC.

I guess I have not much option in not ordering a new shaft, as the KACR is broken.

I will get full retard tomorrow and hookup a drill to the fly wheel and see if it cranks fast enough increase vacuum on the carbs...